General Technical Specifications (Electrical)

STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT

GENERAL TECHNICAL SPECIFICATION

2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc l o 2U5

BHILAI STEEL PLANT

GENERAL SPECIFICATION
FOR
ELECTRICAL SYSTEM
(GS 03)

MECON LIMITED
RANCHI - 834002

No. MEC/S/1901/11/38/0/00/00/F1889/R2 JULY, 2007

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CONTENTS

Sl.No Chapter No. Contents Page No
1.0 Contents 2
2.0 1.01 General 7
3.0 1.01.01 Standards 7
4.0 1.01.02 Climatic Conditions 7
5.0 1.01.02.01 Environmental condition 7
6.0 1.01.02.02 Ambient conditions of shop units 8
7.0 1.01.03 Standard Voltage levels 9
8.0 1.01.03.01 Symmetrical short circuit ratings 10
9.0 1.01.03.02 Permissible variations 10
10.0 1.01.04 Criteria for selection of voltage levels for motors &
Power devices
11
11.0 1.01.05 Design criteria & reliability conditions 11
12.0 1.01.05.01 Power Distribution system 11
13.0 1.01.06 Cabling 12
14.0 1.01.07 Motor starting and permissible voltage dips 13
15.0 1.01.08 Maximum Demand of MCC 13
16.0 1.01.09 Incomer rating selection for MCC 14
17.0 1.01.10 Outgoing Feeder Selection for MCC 14
18.0 1.01.11 Power Factor Compensation 15
19.0 1.01.12 Cable selection 15
20.0 1.01.12.01 Incomers of MCC / PDB / MLDB 15
21.0 1.01.12.02 Motors 15
22.0 1.01.12.03 Illumination System 15
23.0 1.01.12.04 Automation System 16
24.0 1.01.12.05 General 16
25.0 1.01.13 Ventilation and Air Conditioning 16
26.0 1.01.13.01 Substation building, MCC Rooms and Cable Cellar 17
27.0 1.01.13.02 Electrical rooms with electronic equipment / Central
Control rooms
17
28.0 1.01.13.03 Small local Control Rooms/pulpits 17
29.0 1.01.13.04 Cable tunnels 17
30.0 1.01.13.04 General 18
31.0 1.01.14 Variable Speed AC Drives. 18
32.0 1.01.15 Control Philosophy 18
33.0 1.01.15.01 General 18
34.0 1.01.15.02 Modes of operation 19

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35.0 1.01.16 Spares Philosophy 21
36.0 1.01.17 Uninterrupted Power Supply (UPS) 21
37.0 1.01.18 Colour coding of equipment 22
38.0 1.01.19 Drawings and documents 22
39.0 1.02 EQUIPMENTS 23
40.0 1.02.01 TRANSFORMER 23
41.0 1.02.02 VCB (Transformer Isolation) 32
42.0 1.02.03 415V Switchgear 36
43.0 1.02.04 LT busduct 45
44.0 1.02.05 Power Distribution Board (PDB) 48
45.0 1.02.06 Motors & Field devices 49
46.0 1.02.06.01 Low voltage squirrel cage induction motors 49
47.0 1.02.06.02 Low voltage slip ring induction motors 51
48.0 1.02.06.03 Roller Table Motors (Torque motors) 54
49.0 1.02.06.04 High voltage squirrel cage induction motors 54
50.0 1.02.06.05 Synchronous Motors 57
51.0 1.02.06.06 LT Inverter Duty Motor 59
52.0 1.02.06.07 DC Electromagnetic brake 63
53.0 1.02.06.08 Field Switches 64
54.0 1.02.06.09 Power Resistance 64
55.0 1.02.07 Individual Drive Control Level 65
56.0 1.02.07.01 Variable Frequency Drive (VFD) 65
57.0 1.02.07.02 AC Line Reactor 73
58.0 1.02.07.03 Load Commutated Inverter (LCI) 73
59.0 1.02.08 Intelligent type MCC 75
60.0 1.02.09 Stand Alone Starter 83
61.0 1.02.10 Soft Starter 86
62.0 1.02.11 Specifications of major components 91
63.0 1.02.11.01 Moulded Case Circuit Breaker (MCCB) 91
64.0 1.02.11.02 AC Contactors 92
65.0 1.02.11.03 Current transformers 93
66.0 1.02.11.04 Control transformers 93
67.0 1.02.11.05 Indicating instruments 93
68.0 1.02.11.06 Thermal Overload Relays 94
69.0 1.02.11.07 Magnetic Overload Relays 94
70.0 1.02.11.08 Push Buttons 95
71.0 1.02.11.09 Indicating Lamps 95
72.0 1.02.11.10 Miniature Circuit Breakers (MCB) 96
73.0 1.02.11.11 Selector Switches 97
74.0 1.02.12 Local Control Stations 97

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75.0 1.02.13 Control Desk 98
76.0 1.02.14. Control System Concept And Philpsophy 100
77.0 1.02.15. Automation System 101
78.0 1.02.15.01 General 101
79.0 1.02.15.02 Programmable Logic Controller (PLC) 111
80.0 1.02.15.03 Human Machine Interface (HMI), Work Station &
Engineering Station
120
81.0 1.02.15.04 Server 122
82.0 1.02.15.05 Software 123
83.0 1.02.16 Large Screen Display System 126
84.0 1.02.17. Uninterrupted Power Supply 127
85.0 1.02.18 Electronic Weighing System 135
86.0 1.02.19 CABLES 141
87.0 1.02.19.1 HT Cables 141
88.0 1.02.19.1.i 33 kV kV(UE) XLPE cables 141
89.0 1.02.19.1.ii 6.6 / 11 kV (UE) XLPE cables 142
90.0 1.02.19.2 LT CABLES 143
91.0 1.02.19.2.i 1.1 kV Power Cable 143
92.0 1.02.19.2.ii 1.1 KV Grade Control Cable 144
93.0 1.02.19.2.iii 1.1 KV Grade Screened /Special Cable 145
94.0 1.02.19.2.iv Heat resistant cable 147
95.0 1.02.19.2.v Trailing cable 147
96.0 1.02.19.2.vi Flame Retardant Low Smoke (FRLS) Cables 148
97.0 01.02.20 EOT Cranes
Trolley lines and power supply arrangements for
cranes
148
98.0 1.02.21 Erection Specification 164
99.0 1.02.21.01 Guidelines for design of system and engineering the
layout of electrical equipment.
164
100.0 1.02.21.01.01 General 164
101.0 1.02.21.01.02 Electrical premises 164
102.0 1.02.21.01.03 Control rooms/pulpits 165
103.0 1.02.21.01.04 Cable tunnels 165
104.0 1.02.21.01.05 Cable shafts 166
105.0 1.02.21.01.06 Clearances inside the electrical rooms 166
106.0 1.02.21.01.07 Transformer rooms 167
107.0 1.02.21.02 Guide-line for erection of Electrical equipment
and accessories
167
108.0 1.02.21.02.01 General 167
109.0 1.02.21.02.02 Rotating machines 168

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110.0 1.02.21.02.03 Sheet metal enclosed panels, open control panels,
control desks and boxes
169
111.0 1.02.21.02.04 Static converters 170
112.0 1.02.21.02.05 Transformers and reactors 170
113.0 1.02.21.02.06 Battery installation 171
114.0 1.02.21.02.07 Busbar 171
115.0 1.02.21.02.08 Crane Trolley Lines 171
116.0 1.02.21.02.09 Resistance Box 171
117.0 1.02.21.02.10 Cables Installations 172
118.0 1.02.21.02.11.1 Laying in tunnels/surface ducts/on structures 172
119.0 1.02.21.02.11.2 Structures for cable laying 173
120.0 1.02.21.02.11.2 Cable Joint/termination accessories 176
121.0 1.02.21.02.12 Exposed conduits 177
122.0 1.02.22 Earthing and lightning protection 177
123.0 1.02.22.01 Earthing 179
124.0 1.02.22.02 Conductor sizes for ground connections 179
125.0 1.02.22.03 Earthing electrodes 179
126.0 1.02.22.04 Lightning protection 180
127.0 1.02.23 Repair network 181
128.0 1.02.23.01 General 181
129.0 1.02.23.02 Switch socket outlets 181
130.0 1.02.23.03 Cables 181
131.0 1.02.24 Ventilation and Air-Conditioning of Electrical
Premises/Control Rooms
182

132.0 1.02.24.01 General 182
133.0 1.02.24.02 Switchgear rooms, MCC rooms, Cable cellar 182
134.0 1.02.24.03 Electrical rooms with electronic equipment 182
135.0 1.02.24.04 Central Control rooms, Rooms for PLC, Servers,
Computers and Level-1/2 automation system
equipment.
183
136.0 1.02.24.05 Small local Control Rooms/pulpits 183
137.0 1.02.24.06 Cable tunnels and basements 183
138.0 1.02.25 Testing 183
139.0 1.02.25.01 Type & Routine 184
140.0 1.02.25.01.01 Transformers 184
141.0 1.02.25.01.02 Busduct 184
142.0 1.02.25.01.03 Power Control Centre and LT switchgear 185
143.0 1.02.25.01.04 Load Break Isolator 185
144.0 1.02.25.01.05 Current Transformer and voltage transformer 185
145.0 1.02.25.01.06 Final Test of Materials of Grounding and lightning 186

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system
146.0 1.02.25.01.07 Cables 186
147.0 1.02.25.01.08 Motors 187
148.0 1.02.25.01.09 Site tests and checks 188
149.0 1.02.25.01.09.01 General 188
150.0 1.02.25.01.09.02 Trial Run Test 188
151.0 1.02.25.01.09.03 Acceptance test 188
152.0 1.02.25.01.09.04 Site Tests 188
153.0 Appendix
Selection of Power Components & Wiring for
Continuous Duty Cage Motor Drives
192
154.0 1.02.26 Illumination 193

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10.0 ELECTRICAL
1.01 General
1.01.01 Standards

The design, manufacture, assembly and testing as well as performance (including
safety, earthing and other essential provisions) of equipment and accessories covered
under this specification shall, in general, comply with the latest issue of :

Latest applicable Standards and Codes of Practices published by Indian Standards
Institution (BIS).
Latest IPSS (Interplant Standards for Steel Industry)
Latest Indian Electricity Rules & statutory requirements of Central Govt. and State
Govt.

In case, the tenderer is not in a position to comply fully with certain IS / IPSS
specifications or in respect of certain items for which there are no IS / IPSS
specifications, the tenderer may base his proposals on IEC recommendations or other
reputed national or international standards subject to the approval of the Purchaser.

The components and materials used and the equipment supplied shall conform to high
standards of design, engineering and workmanship and shall be suitable for efficient
operation and reliable service in steel plant conditions .

All equipments supplied and all work done including system design and detailed
engineering shall also comply with the statutory requirements of Govt. of India and the
respective governments of state in which the plant is situated . The installation shall
also confirm to Indian Electricity Act and Indian Electricity Rules.

In case of any contradiction between the data given in the Technical Specification (TS)
and this General Technical specification (GTS), data given in the Technical
specification (TS) shall prevail.
1.01.02 Climatic Conditions

1.01.02.01 Environmental condition

Sl.No Environmental condition Data
1.0 Maximum ambient temp. 50 deg. C
2.0 Maximum Humidity 100 % does not occur simultaneously
with maximum temperature.
3.0 Height Less than 1000 M.

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Sl.No Environmental condition Data
4.0 Environment Dusty & Corrosive

1.01.02.02 Ambient conditions of shop units

Generally following maximum ambient temperature shall be considered in different
units of the integrated steel plant .

Sl.No Area Data
A. Coke Ovens & Byproduct Plant
1. Battery cellar + 55 Deg. C
2. Battery Top + 60 Deg. C
3. Coal Tower, Intermediate & End benches + 50 Deg. C
4. Pusher Car & Loco + 50 Deg. C
5. Guide Car & Charging Car + 60 Deg. C
B. Blast furnace
1. Cast house + 60 Deg. C
2. Furnace proper + 55 Deg. C
3. Stock house + 50 Deg. C
4. Pump house + 50 Deg. C
5. Stove area + 55 Deg. C
6. GCP area + 50 Deg. C
7. Other areas + 50 Deg. C
C. Steel Melting Shop
1. Converter Bay + 60 Deg. C
2. Mixer Bay + 55 Deg. C
D. Continuous Casting Shop
1. Casting bay + 60 Deg. C
2. Withdrawal , straightening and gas cutting areas + 55 Deg. C
E. Hot rolling mills
1. Generally + 55 Deg. C
2. Finishing bays + 50 Deg. C
3. Foundry + 55 Deg. C
4. Auxiliary Shops + 50 Deg. C
F. Other areas + 50 Deg. C
G. Electrical rooms
1. HT/LT substation & MCC rooms (ventilated) + 45 Deg. C
2. Cable basements / tunnels (ventilated) + 45 Deg. C
H. Control Rooms
1. Control rooms Air conditioned + 24 Deg. C

Equipment selection and de-rating shall generally be based on ambient temperature of
50 Deg.C. For specific areas and shops, the ambient temperature conditions indicated
above shall be taken into consideration and equipment shall be suitably de-rated
accordingly .

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The equipment offered should be suitable for smooth, efficient and trouble free service
in the tropical humid climate prevailing at plant site and under the ambient temperature
conditions indicated above for the different shops and areas. In hot areas of higher
temperature conditions, the equipment shall be adequately protected against damage
from radiant heat and hot air.

The equipment shall be designed to give efficient and reliable performance under
heavy steel plant conditions and shall be such that the risks of accidental short-circuits
due to animals, birds or vermins are avoided.

1.01.03 Standard Voltage levels:

In case the standard voltage levels to be adopted in the plant are specified in the
Technical specification, it shall be followed. In absence of any details indicated in the
Technical Specification, the following standard voltage levels shall be adopted.
Sl.No Description Data
1 HT AC 11 KV / 6.6 KV , 3 phase, 50 Hz,
unearthed neutral .
2. LT AC 415V, 3 Phase, 50 Hz, 4 wire, solidly
earthed
3. AC control and signaling
voltage
240V, AC + 10% obtained using suitable
control transformers with auto
changeover facility.
4. DC supply voltage 220 Volts / 110 Volts
5. DC control and signaling
voltage
220 Volts / 110 Volts
6. Control voltage for HT
switchgear equipment
110 V DC from battery in HT S/S area.
220 V DC from battery in MSDS area.
7. Special socket outlets for
portable lamps
24V, single phase, 50 Hz, AC obtained
through suitable transformers
8. DC Electro-magnetic brakes 220V, DC, obtained through individual
rectifiers
9. Solenoid valves 24V DC, unearthed
10. Machine tools lighting 24 V AC
11. Sockets for Welding purposes 415V, 100A, 3 pin plus earth with plug
interlocked switch
12. Sockets for hand tools 240V, 15A, 2 pin plus earth with plug
interlocked switch
13. Illumination system 240 V AC for general application.
24 V AC for confined & semi confined
area. (as per IPSS).
14. PLC power supply 240 V AC, 50 Hz, obtained through UPS
(for processor , RIO chassis ,

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Sl.No Description Data
interrogation voltage and output voltage )
240 V AC , single phase from MCC (for
aux. voltage )
15. Monitoring and signaling in
electronic installations, mimic
panels
24V, DC
(Through PLC output for PLC control
boards / desks)
16.
PLC DI interrogation voltage 24 V DC
17.
PLC DO voltage 24 V DC

1.01.03.01 Symmetrical short circuit ratings:

The three phase symmetrical short-circuit ratings of the switchgear at the different
voltage levels shall be as follows unless specifically indicated in the Technical
specification:

Sl.No. Description Data
1. 11 kV switchgear 40 kA for 3 sec .
2. 6.6 kV switchgear 40 kA for 3 sec .
3. 415 V switchgear 50 kA for 1 sec.

1.01.03.02 Permissible variations:

The system / unit / plant / equipment shall be designed so as to be suitable for the
following variations in voltage and frequency unless specifically indicated in the
Technical specification:

Description Voltage Frequency
Permissible variations
with rated performance,
rated current and control
effectiveness maintained
For LT system :-
+10% & -15%
For HT system :-
+6% & -9%
Frequency variation for
both HT & LT shall be +
4%, - 6%
With changes in rated
Current / torque but
without any undesirable
effect on performance
+/- 10% +/- 3%

for control and
regulation equipment
+/- 15% +6%, -6%

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Description Voltage Frequency
with rated performance
and control quality
maintained
Permissible voltage dip at
the HT and LT switch
gear bus during starting of
HT and LT motor
For LT system :-
-15%
For HT system :-
- 10%
Frequency Variation for both
HT & LT shall be
considered as +4%, -6%.

1.01.04 Criteria for selection of voltage levels for motors & Power devices:
AC squirrel cage induction motors of ratings up to 200 kW and slip ring motors up
to 250 kW shall be fed at LT, 415V, 3 phase , 4 wire , 50 Hz with DOL.
AC motors of ratings in excess of 200KW upto 1000 KW and beyond 1000 KW
shall be connected to 6.6 KV U/E and 11 KV U/E power supply system
respectively for DOL starting. The HT voltage level shall be as specified in the
Technical specification.
AC squirrel cage induction motors of ratings up to 200kW may be fed at LT, 415V,
3 phase 4 wire 50 Hz, with VFD where speed control is required.
For motor rating more than 200 KW up to 1000 KW shall be provided with VFD
where speed control is required , the rated voltage of the motor shall be 690 V .
Soft starters with DOL bypass shall be provided for drives ratings ranging from 90
KW to 200 KW where full torque load starting and speed variation is not required

1.01.05 Design criteria & reliability conditions:

1.01.05.01 Power Distribution system

The power distribution system shall meet the following guide lines:
Suitable numbers of 415V LT Substation (LTSS) shall be provided for feeding
different Motor control centers and auxiliaries power distribution boards as required
for the plant.
The MCC / PDB / MLDB shall be fed from LTSS.
Suitable numbers of 415V Motor control centers shall be provided for feeding
power supply to motors of rating 90 KW and below.
Field located Power supply panels (MCB DB / Local Starter Panels) shall be fed
from MCC.
Electronic relays with display (for motor rating of 37 KW and above) shall be
considered in place of thermal overload relays as follows :
o Electronic over load relay protection for motors below 15 KW for crane
application and for reversible drives. Electronic over load relay / MPCB
protection for motors below 15 KW for other application
o EOCR for OC & EF , unbalance protection for motors rated 18.5 KW to 90 KW
o Composite motor protection relay with OL , OC ,EF , unbalanced & locked
rotor protection with digital display for motor rated 110 KW and above .
o EOCR shall be used only for non intelligent feeders .
Motor of rating above 90 kW shall be provided with independent Motor control
Panel (MCP) which shall be fed directly from LTSS. Power devices like MCCB,

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Contactors, intelligent motor control relays / microprocessor based MPR (for non
intelligent controllers) etc. shall be located in independent MCPs. Each MCP shall
be located in MCC room by the side of the respective group MCC.
VFDs shall be provided for process fans / pumps as per technological requirement
A dedicated MCC with two incomers (one from PCC and other from DG set or any
emergency power source) and bus coupler shall be provided for catering to all
emergency loads of the shop/unit.
MCCB, contactor and overload relay rating for the low voltage general purpose
induction motors shall be selected as per type-2 coordination chart of selected
manufacturer. However the minimum contactor rating shall be 32A.
All the important drives (all 6.6 KV , 11 KV & 690 V motors) should be provided
with suitable CBM systems such as vibration monitoring, current signature,
temperature etc. Information from CBM systems to be interfaced to HMI system as
well as plant-wide CBM system.

1.01.05.02 The capacities of the transformer shall be selected as per the following guidelines:

MD of MCC, shall be calculated as per the guidelines given in clause no. 1.01.08 of
the General Technical Specifications.
Load factor of 0.9 shall be considered for motors being fed from 415V LTSS . The
load factor shall be applied on the kW rating of motors. Only working motors shall
be considered.
Load of lighting transformer shall be considered as per the kVA rating of
transformer.
Where ACDB is provided along with the LTSS, then load of ventilation system with
0.9 load factor shall be considered.
Diversity factor of 1.1 shall be used on the summation of MDs of various MCCs,
motors, lighting transformers and ACDB.
Spare capacity of 20% shall be provided for future use.
Each LTSS shall be fed from two identically rated transformers.
In case of outage of any transformer, the remaining transformer shall be loaded up
to 80% of their rating.
Transformer shall be selected from standard rating of 1000/2000 KVA only
It shall be ensured that when all the loads are in operation and the largest motor is
started, the voltage drop at the motor terminals shall not be more than 15%.

1.01.05.03 The rating of outgoing feeders of LTSS shall be selected from standard circuit breakers
ratings of 800A, 1000A & 1600 A only considering the load requirement and derating
factors due to ambient temperature as well as for the mounting of the component in the
switch board. CTs shall be selected considering the actual loads.

1.01.05.04 11kV / 6.6 kV panel mounted load break switches with earthing switches of adequate
rating shall be provided before feeding the transformer . Transformer pens shall also
be provided with push button station for switching ON/OFF the corresponding 11kV /
6.6 kV upstream feeding circuit breaker.
In case of transformer of rating 5 MVA and above , following arrangement shall be
followed:
LBS (isolator) shall be provided in the transformer room, when transformer is fed
from remote HT switchboard.
Lockable type PB shall be provided in transformer room when transformer is fed
from HT switchboard located in the same building.

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1.01.05.05 AC squirrel cage induction motors shall be used for drives requiring speed control.
For all electrical machines wherever strip wound coils are used detail drawing is to be
provided in soft copy.
Use of DC motors, AC slip ring motors shall be avoided to the extent possible.
Manufacturing drawing for parts stator coils, slip ring, brush, brush holder in slipring
motors and drawings of parts of armature coil, commutator, brush and brush holder
in DC machine shall be provided in soft copy.
Sizes of conductors used in motors shall be preferred sizes as per IS.
Sufficient spares of parts of all electrical machines shall be provided..

1.01.06 Cabling
Tenderer shall note the following regarding cabling:-
Sl. No. Requirement Remarks
1.0 Inter shop cable routing Through overhead cable gallaries /
structure or walkable cable tunnel.
2.0 Substation building RCC cable basement of minimum 3.0
metres clear height .
3.0 MCC room RCC cable trench / false floor at
bottom of MCC
4.0 Illumination system cable laying in
all units.
1. Unarmoured FRLS cables through
MS black conduits in open area.
2. Armoured FRLS without conduit in
covered area.
3. Unarmoured FRLS cables through
concealed MS black conduits in
buildings like control room, office
building etc.

1.01.07 Motor starting and permissible voltage dips:
Voltage dip on starting of the largest L.T. motor shall be limited to 15% of the
nominal voltage at the motor terminals.
Maximum allowable voltage drop in any feeder under steady state condition shall
be maintained as follows :-

Total voltage drop during running : 6 %
LTSS to motor : 6 %
LTSS to MCC/PDB/MLDB if in same building : 2%
MCC to motor for above case : 4%
LTSS to MCC/PDB/MLDB if in different building : 3%
MCC to motor for above case : 3%

Voltage drop at the terminal of other equipment shall be as per the minimum voltage
required for proper functioning of the equipment recommended by their manufacturers.

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1.01.08 Maximum Demand of MCC

Maximum demand (MD) of the MCC shall be calculated considering the following:

1. Working load of the MCC shall be calculated based on the motor kW rating.
2. The load factor shall be considered as follows:

For continuous drives 0.9
For intermittent drives like sump pumps etc. 0.6
For electrically actuated valves / dampers 0.2
For maintenance loads like hoists, cranes etc. - 0.4
3. Welding and utility socket loads shall not be considered for calculation of
maximum demand.
4. Load factor shall be applied on the kW rating of motor.
5. Diversity factor shall be considered as one.
6. Spare feeders shall also be considered for calculation of maximum demand as
per guidelines indicated in Sl. No.2
7. Load of power supply feeders shall be corresponding to the load being fed with
0.9 load factor.
8. Cyclic load shall be converted to continuous load and shall be used for MD
without load factor. (e.g. 22kW motor at 40% duty factor will have continuous
load as 22xsquare root of 0.4)
9. 20% spare capacity shall be included in maximum demand for future use.

1.01.09 Incomer rating selection for MCC

1. All ACB I/C shall be intelligent type having standard protocol for
communication
2. Incomer of the MCC shall be ACB / MCCB having fault level of 50 kA for 1 sec.
MCCB shall be provided for ratings 630A and below. Standard ratings of ACB /
MCCB shall be provided.
3. Continuous current rating of the incomer shall be corresponding to MD of the
MCC.
4. In case of PMCC where MCC is directly fed from transformer, Continuous
current rating of Incomer shall be equal to current rating of transformer.
5. In case ACB / MCCB is rated for 40 deg.C then continuous de-rated current in
enclosure and for ambient temperature shall be more than MD / transformer
current rating.
6. Main bus bar rating of MCC shall be equal to incomer rating.
7. Voltage rating of the breaker shall be equal to the incomer voltage of the
system with rated tolerance (as mentioned in the relevant chapter).
8. Each MCC shall be provided with manual operated, draw out two nos.of
incomers and one no. of bus coupler . Incomers and bus coupler shall be ACB
/ MCCB. ACB / MCCB shall be provided with overload, short circuit, earth fault
and under voltage releases.
9. Each incomer and bus coupler shall be provided with indicating lamps for each
phase for incoming supply and digital ammeter and voltmeter for measuring
current in each phase and line to line voltages of MCC bus. ON, OFF and
TRIP indicating lamps shall also be provided.
10. Incomer and bus coupler shall be mechanically interlocked in such a way that
at any given time only two breakers can be closed. Electrical interlocks shall be
provided as follows:

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When both incomer ACBs / MCCBs are ON then bus coupler ACB / MCCB
can not be switched ON.
When incoming power to one of the incomer is not available then bus
coupler can be switched ON manually.
When incoming power to the incomer breaker is restored then incomer can
be switched on manually and bus coupler will trip automatically.
Bus coupler closing is not permitted if the incomer trips on fault.
1.01.10 Outgoing Feeder Selection for MCC

1 Motor feeders shall be provided with MCCB, contactor, electronic thermal
overload relay (with indication lamp for motor rating 37 KW and above) and
other auxiliary equipment like selector switch, indicating lamps, auxiliary
contactors etc. as per requirement (for non intelligent MCC) .
2 Overload protection device shall be electronic overload relay as indicated in
specification. In case electronic overload relay is provided then MCC module
shall be provided with indicating lamps.
3 Motor control panel (MCP) for motor ratings above 90 KW shall be provided
with motor protection numerical relay (for non intelligent MCC) as per
specification. Other components same shall be same as motor feeders of
MCC.
4 Power supply feeders shall be provided with MCCB and ammeter.
5 All PDB feeding non-critical loads shall be single fed system

1.01.11 Power Factor Compensation

In case power factor correction at LT level is specified in specification then APFC shall
be provided in PMCC / LTPDB. The capacitor bank shall be so designed that the
overall power factor of the system shall be 0.95.

1.01.12 Cable selection
.01 Incomers of MCC / PDB / MLDB
Cable size for incomer of MCC & PDB shall be selected on the basis of current
rating corresponding to MD and voltage drop.
Cable size for incomer of MLDB shall be selected on the basis of current rating
corresponding to lighting transformer and voltage drop.
The standard size of the cable shall be 3.5 x 240sq.mm. of type AYFY as per
IS:1554 (A2XFaY for XLPE insulated cables as per IS : 7098 Part-1).
For calculating the current rating of power cables de-rating factor of 0.65 shall be
used.
.02 Motors
Cable size for LT motors shall be selected on the basis of rated nameplate current
and starting & running voltage drop as per specification.
Cable size for HT motors shall be selected on the basis of rated nameplate current,
starting & running voltage drop as per specification and short circuit capacity of the
system. The cable size shall be calculated based on the breaker opening time of
0.35 seconds.
Minimum size of cable for LT motors shall be 4x6sq.mm. of type AYRY as per
IS:1554 and maximum size of cable shall be 3.5 x 185 sq.mm. of type AYFY as per

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IS:1554. In case copper conductor cables are used then the maximum & minimum
size of cable shall be one size lower than as indicated above for aluminium cables.
For motors rated up to 2.2 kW and actuators of motors of valves and dampers
cable size of 4x2.5sq.mm. of type YRY as per IS:1554 shall be used.
For calculating the current rating of power cables de-rating factor of 0.65 shall be
used.

.03 Illumination System
The minimum size of the cable for feeding power to SLDB or MCBDB having 32A
incomer shall be 4x25sq.mm of type AYFY/AYY as per IS:1554.
Cable size for MCBDB to light fittings shall be 2x2.5sq.mm. or 4x2.5sq.mm as per
the configuration of fittings. The cable type shall be YRY/YY as per IS: 1554.
In case of concealed wiring, single core, PVC insulated, stranded copper conductor
wire of size 1.5sq.mm in MS conduit shall be used. For utility sockets, cable size
shall be 4sq.mm.
Laying of cables shall be decided as per details indicated in the specification.
Energy efficient smart lighting fixtures and controls to be used for buildings.

.04 Automation System
All control cables connecting I/Os from field to marshalling panel of PLC or remote
I/O panel shall be of stranded copper conductor of type YRY as per IS: 1554 and of
size 1.5 sq. mm. minimum for PLC I/O or as suitable.
Communication bus shall be laid in GI pipe. The route for redundant
communication bus shall be different.

.05 General
Minimum size of the cables used in LT power circuits shall be 6sq.mm per core if
with aluminium conductor or 4sq.mm per core if with copper conductor. Maximum
cable size shall be 240sq.mm for incomers to MCCs, PCCs etc. The minimum
cable size selected for applications in the power circuits of cranes and other
moving mechanisms shall be 6sq.mm per core copper. All power cables shall be
3.5 / 4 cores.
For power supply to moving mechanisms subject to vibrations, flexible copper
cables preferably of single core should be used. In these cases, a separate core
should be provided for earthing. For hoists with flexible / festoon cable system,
power supply shall be through butyl rubber / EPR insulated PCP/CSP sheathed
flexible cables. Cables used for circuits of tacho generators, brakes, solenoids,
field windings and secondary windings of measuring transformers shall be copper
conductor with cross-sectional area not less than 2.5sq.mm per core.
For control circuits, PVC insulated and PVC sheathed multicore cables with copper
conductors having a minimum cross-sectional area of 2.5sq.mm per core shall be
used. The number of cores may be standardized as 3, 5, 7, 10, 14, 19, and 24.

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Each core of control cable with 7 core and above shall be numbered at every 1-
meter interval.
For signals like mA and mV, special screened/shielded cables shall be used.
20% spare cores shall be provided with minimum 1 spare core in multi-core control
and signal cables.
1.01.13 Ventilation and Air Conditioning

The various electrical rooms of the plant shall be provided with ventilation and air
conditioning facilities, as indicated below. Air dryer units to be provided wherever air is
being used for purging / cleaning purposes .

.01 Substation building, MCC Rooms and Cable Cellar

All HT/LT substations, switch gear rooms and MCC rooms, cable basement/cellars
which do not house any electronic equipment but contain only electrical equipment,
shall be pressurized up to 2-3mm water column with cooled air washer system to
maintain the room temperature at 45 deg.C irrespective of ambient temperature.
Suitable capacity fan and pumps (1W+1S) shall be provided for each unit.

.02 Electrical rooms with electronic equipment / Central Control rooms

The electrical rooms housing electronic equipment like PLC , computers, Servers,
Level II systems, Remote I/Os, AC and DC variable speed drives , soft starters , UPS
, electronic weighing panels , telephone exchange equipment etc. shall be installed in
air-conditioned environment with pressurization to maintain the following conditions:
Room temperature : Shall not be more than 35deg.
Relative humidity : 50 to 60%
Pressurization : 2-3 mm WC
Temperature gradient : 2 Deg. C/h
For central control rooms standby air conditioners shall also be provided.
Separate room, as part of control room shall be provided with window AC units.

.03 Small local Control Rooms/pulpits

The small control rooms/pulpits shall be air-conditioned to maintain the following
conditions:
Room temperature : 24Deg. C
Relative humidity : 50-60%
Pressurization : 2-3 mm WC

.04 Cable tunnels

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These shall be ventilated with fresh filtered air to maintain exit air temperature at
40deg.C.
Cable tunnel ventilation shall be sectionalized to maximum length of 150 m.
Temperature rise shall be limited to 3-5 deg.C above atmospheric dry bulb
temperature subject to a maximum of 40deg.C at the exit of air from these
premises.
Partition door between basement and the cable tunnel shall be air tight and of fire
retardant material.
All cable tunnels shall be properly ventilated.

.05 General

Necessary ducting with air diffuser shall be provided.
Ventilation and air conditioning system shall be interlocked with fire detection
system for safety.
Airtight double door arrangement shall be provided for electrical rooms, control
rooms and basement.

1.01.14 Variable Speed AC Drives.

1. Continuous current of AC drives shall be decided as indicated below:
For continuous duty drives (variable torque drives) like pumps fans etc. :
115% of motor full load rated current.
For motion control drives and intermittent duty drives : 150% of motor full load
current.
For constant torque drives and multi motor drives like moving machines,
hoisting etc. : 150% of the summation of rated motor current for multi motor
drives and rated motor current for hoisting drives.
2. All AC drives shall be rated for 380 480V, three phase with voltage variation as
specified.
3. Isolation transformer shall be provided for drive more than 75 KW and line reactor
shall be provided for drive less than 75 KW in incoming (line) side .
4. For 4 quadrant operation applications active front end, low harmonics, regenerative
AC drive shall be provided for main drives , process cranes and major auxiliary
drives..
5. For crane applications in hot areas where ambient is more than 50 deg.C thyristor
converters (ASTAT or SIMOTRAS) shall be used .
6. Current rating of AC drive as innumerated above shall be calculated after de-rating
to specified ambient temperature.

1.01.15 Control Philosophy
.01 General

Adequate and appropriate automation systems shall be designed and engineered
using state-of-art and field proven technology to facilitate monitoring, control and all
other functions associated with operation of all the plant/shop units through user-
friendly human-machine interfaces.

The Automation system shall be designed with geographical & functional distribution of
hardware in a multi-level hierarchy, viz. Level-0, Level-1, level-2, level-3 etc, as

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applicable, to meet specific plant requirements for monitoring, control, process
visualization & optimization of all the plants/ shop units.

The automation system shall be structured in general, considering the following
hierarchical levels:

Level - 0

This level, also called field level, is functionally responsible for generation,
transmission & conversion of signals for the process parameters compatible to the
higher level equipment as well as signal based activation for the final control
elements.

This level is realized based on the primary sensing elements, proximity switches,
converters, microprocessor based intelligent systems and final control elements.
The components of this level shall be grouped and distributed geographically
around the plant as per main process equipment location.

Level-1

This level, also called supervisory level, is functionally responsible for supervision
of the individual process equipment & functions, monitoring, control, visualization
and regulation of process parameters to the desired level based on the signals
generated from the field level. This level is also responsible for processing of
signals for generating compatible control commands to control the process
parameters by activation of the final control elements.

This level is realized based on the controllers & systems, input & output systems,
data base units, data communication, visualization system (HMI stations) and
interface units for connectivity to the other levels of the automation system. In
addition to routine PID functions, advanced process optimization functions
comprising special control algorithms, mathematical computations etc. will be able
to permit distribution of control and data acquisition functions throughout the entire
plant.

Level-2

This level is functionally responsible for the process control functions through the
Level-1 automation system by process guidance & optimization and control of
process parameters to the desired level of perfection based on the available
signals from the supervisory level. This level is also called process control level
and is responsible for generating set points / control commands to the Level-1
equipment based on the pre-loaded process specific mathematical models. This
level is realized based on the process computer & its own data base units, input &
output systems, data communication systems, visualization system (HMI stations)
and interface units for connectivity to the other levels of the automation system.
Level-2 automation system has been covered under a separate General
Specification.

The Level-1 automation shall basically comprise:

A Programmable Logic Controller (PLC) based automation system

.02 Modes of operation

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The following modes of operation shall be provided, it shall be in line with changes
suggested in respective TS.

A. Local

Local Control Station (LCS) shall be provided for all motor and actuator drives.
LCS shall have required numbers of push buttons for operation of drive .
In Local Mode, operation of single drive / equipment from LCS shall be
provided. This mode of operation will generally be for test and repair
purposes. To enable the testing of individual equipment all the interlocks shall
be bypassed in this mode. However all critical equipment / drives shall be
provided with hard-wired interlocking in MCC.

However for failsafe operation, potential free contact of Push Button from LCS
and a potential free contact of field safety sensor shall be hard wired to MCC
for safety reasons.

Drive can not be started from any place if the selector switch is in OFF
position.

B. Remote

In Remote mode, the equipment can be started from control room only. This
remote mode is further divided into following three modes:

Operator mode
Auto mode
Computer mode (Level-2 system)

Once the remote mode of operation is selected then from HMI with help of key
board / mouse / soft keys above three modes of operation can be selected.

Operator Mode

Under this mode it shall be possible to monitor & control the plant based on set
points / commands given by operator through keyboard and the control,
sequential operation of various mechanisms in the required sequence shall be
executed by PLC with all interlocks. In this case all the changes / operations
are operator initiated.

Auto Mode

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This is the normal mode of operation of the plant. In this mode, the desired
values (set point) of the parameters of process control loop will be set via
keyboard of the HMI and sequencing and logic functions will remain operative
through the PLC as per application software.

There shall be a provision for group start of drives in individual section with the
required interlocks, logic and sequencing between the individual drives.

Computer Mode

In this mode the entire plant will be controlled through level-2 system. All the
required set points will be generated by level-2 computer as per the
mathematical model calculations based on the inputs received from the field.
In case of failure of the level 2 system all the set points will be automatically
shift to operator mode of operation.

1.01.16 Spares Philosophy

The spare philosophy for various equipment shall be as follows:

1. LTSS, MCC, PDB and MLDB shall be provided with 20% spare feeders or one of
each type whichever is higher with minimum of two numbers in each section
2. LDB, MCBDB for lighting and MCB DB for utility sockets shall be provided with
minimum 9 nos. of spare feeders.
3. DC MCB DB shall be provided with 8 nos. of spare feeders.
4. ACDB of UPS shall be provided with 40% spare feeders.
5. 20% spare terminals shall be provided in each module of MCC, MCP and each
ACB panel.
6. 20% spare terminals shall be provided in all junction boxes, LCS and local
control panels / local starters.
7. Control desk and control cabinet shall be provided with 30% spare terminals.
8. Marshalling panel of MCC and PLC shall be provided with 30% spare
terminals.
9. Relay panels / relay modules shall have 20% spare relays of each type fully
wired up to the terminal blocks.
10. 20% spare interposing relays fully wired up to the terminal blocks shall be
provided in PLC panels.
11. 10% spare components of each type shall be provided in each control desk
/control cabinet / signaling panel.
12. Spare I/O philosophy for PLC shall be as follows:

Min. of 20 % of I/O modules used (with at least one module of each type)
for input and output shall be offered as spare for each programmable
controller and the same shall be mounted and wired to the terminal block
in the cubicle suitably.
No. of spare Channel per card shall be 20 %.
Provision shall be provided with empty slots for future expansion for 20%
I/O modules.
Minimum 50 % spare memory capacity shall be available in the system for
Purchasers use after loading of application and system software.

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01 nos. of DI & DO card per PLC shall be provided as spare .

1.01.17 Uninterrupted Power Supply (UPS)

UPS shall meet the following requirements:

1. Hot standby dual redundant UPS system shall be provided. Each UPS shall be
rated for full capacity and under normal condition one UPS shall be sharing the
total load. In case of failure of any UPS second UPS shall take the full load.
2. Spare capacity of UPS shall be 60 %.
3. Load factor or diversity factor shall not be considered while calculating the load on
UPS.
4. Two separate power supply from different sources shall be provided to UPS one
for UPS and the other for Bypass.
5. Bypass supply to equipment shall be through constant voltage transformer.
6. UPS and SMF batteries shall be located in air conditioned room.

1.01.18 Colour coding of equipment .

PAINT SHADE NO. AS PER SL.
No.
DESCRIPTION OF EQUIPMENT COLOUR
IS 5 : 1991 EQUIVALENT
RAL CODE
I. MOTORS
1. 11 kV/6.6 kV motors Traffic Grey A 631 7042
2. 415 V LT AC motors Silver Grey 631 7030
II. MOUNTED ELECTRICS
1. Equipment installed on or along with
motors viz. Tacho generators, brake
etc.
Same as that
of motor

2. Equipment installed on mechanism
but separate from motor viz. Limit
switches, pull chord switches, belt
sway switches, speed switches, load
cells, photo electric relays etc.
Traffic Grey A 631 7042
III. CONTROL GEAR
1. Drive panels, soft starter panels ,
UPS panels, PLC, Relay panels,
MCC, PDB, MLDB, LDB, etc.
including crane control panels
Light grey 631 7035
2 Lighting distribution and power
distribution board
Light grey 631 7035
3. Fire fighting panel Post office red 538 3002
4. Local control box, Junction box Light grey 631 7035
5. Control desk Light grey 631 7035
6. Pulpit equipment Light grey 631 7035
7. Telecommunication panel Smoke gray 692 7014
IV. MISCELLANEOUS
EQUIPMENT

1. Junction boxes Light gray 631 7035
2. Conduit/pipe pull boxes Light gray 631 7035
3. Light fittings Light gray 631 7035

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PAINT SHADE NO. AS PER SL.
No.
DESCRIPTION OF EQUIPMENT COLOUR
IS 5 : 1991 EQUIVALENT
RAL CODE
4. 415 V Welding sockets Brilliant green 221 6010
5. 230 V Power sockets Light orange 557 2000
6. 24 V transformer sockets, lamp sets
etc.
Canary yellow 309 1016
7. Earthing strip Black

1.01.19 Drawings and documents :-

All the electrical drawings shall be prepared on CAE (computer aided engineering)
packages e.g. SiGraph or any equivalent software package . The package shall have
the facility to connect all the relevant drawings with ERP / SAP package .It must be
OODB(Object Oriented Data Based) type.
The package shall have the facility to interface the most different systems in the plant
establishment and operational process. It shall have the facility to accommodate the
mechanical, civil, structural drawings also.

1.02 EQUIPMENTS
1.02.01 DRY TYPE TRANSFORMER

.1 Standards
Transformers shall comply with the following Indian Standards.

IS: 2026 (1977/1981) - Power Transformers
Parts (I, II, III & IV)

IS: 11171(1985) - Dry Type Transformers

IEC : 60726 - Dry Type Transformers

.2 Mechanical Design

.01 Transformer enclosure shall be welded/ bolted sheet steel construction, free standing,
with suitable size of louvers backed with wire mesh. Base shall be suitably reinforced
to prevent any distortion during lifting. Base channels shall be provided with flat wheels
with pulling eyes and lifting hooks to facilitate handling.

.02 All fasteners and bolts etc. shall be galvanised or zinc passivated. All surfaces to be
painted shall be thoroughly cleaned, made free from rust and given a primary coat of
rust resisting paint followed by two finishing coats of approved shade. Paint shall be
suitable to withstand specific climatic conditions.

.03 The transformer shall be provided with separate weatherproof HV/LV terminal boxes
and disconnecting links on the side of transformer so as to facilitate withdrawal of
transformer without disturbing the HT and LT cables connected to transformer.

.04 Tank shall be suitably designed to withstand harmonics available in the system as well
as generated by the transformer.

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.3 ELECTRICAL DESIGN
i) The transformer shall be cast resin dry type transformer, AN cooled suitable
for indoor installation( in a covered room).
ii) Generally as per IS 2026 Part 1, 2 & 4 of 1977 and Part 3 of 1981.
iii) 3 phase, core type, cast resin.
iv) Rated output, voltage ratio, vector group shall be as specified in technical
particulars for design.
v) Rated frequency 50 Hz, 6%.
vi) Insulation level shall be designed according to the voltages specified below.
Sl. No. Description 11 kV
System
6.6 kV
System
1. Nominal system voltage (kV) 11 6.6
2. Max. system voltage (kV) 12 7.2
3.
One minute power frequency withstand
voltage (kV)
35 28
4. Peak impulse test withstand voltage (kV) 75 60

vi) Transformers shall be capable of delivering rated current at an applied voltage
up to 105% of rated voltage without exceeding the temperature limits.
vii) Overload capacity of the transformer shall be as per IS 6600 - 1972 unless
otherwise specified.
viii) Shall be operable at its rated capacity at any voltage within + 10% of rated
voltage of the particular tap.
ix) Permissible maximum temperature at rated output and principal tap at the
ambient temperature of 50C
Windings (by resistance method) 110C
Core and other adjacent parts of winding 110C
Core and other parts not adjacent of winding
Within safe limits of core and
adjacent materials

x) Transformers shall be designed to withstand the thermal and dynamic stresses
due to short circuits at its terminals or symmetrical/ asymmetrical fault on any
winding. Short circuit withstand capacity for the bolted fault at the
terminals shall not be less than 5 second duration with respect to fault level
specified.

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xi) The maximum temperature at the end of the short circuit duration shall not be
more than 250C with the temperature prior to short circuit
corresponding to maximum permissible overload.
xii) Transformer shall be designed for minimum no-load and load losses within the
economic limit.
xiii) Designed for suppression of harmonics, especially 3rd and 5th.

01. MAGNETIC CIRCUIT
i) Low loss CRGO silicon steel shall be used.
ii) Laminations shall be annealed in a non-oxidizing atmosphere to relieve
stresses and restore the original magnetic properties of CRGO sheets after the
cutting and punching operations.
iii) CRGO sheets shall be coated with insulation varnish compatible with the
sealing liquid.
iv) Insulation to withstand annealing temperature as high as 850 Deg. C and shall
reduce eddy current to minimum.
v) Ducts to be provided to ensure adequate cooling.
vi) Core, framework and clamps arranged and tightened to securely hold
laminations in order to prevent any settling or displacement in case of heavy
shocks during transport, handling or short circuits.
vii) Flux density under specified over voltage or frequency conditions shall be
within the maximum permissible for the laminations. However it shall not
exceed 1.6 tesla.
viii) Transformers shall be designed to withstand 110% over fluxing corresponding
to rated voltage.
ix) Magnetising current shall be maximum 1% of the rated current.

02. WINDINGS
i) Material shall be electrolytic grade copper.
ii) Shall be subjected to shrinkage treatment.
iii) Completed core and winding to be vacuum dried in full vacuum, impregnated
immediately, then dried before casting in resin.
iv) Shall be braced to withstand shocks due to rough handling and forces due to
short circuit, switching or other transients.
v) Permanent current carrying joints in winding and leads shall be brazed.
vi) Coils shall be supported using dried and high-pressure compressed wedge type
insulation spacers.
vii) Insulating materials shall be compatible with transformer liquid under all service
conditions.
viii) Leads to the terminal board and bushings shall be rigidly supported.

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03. INSULATION
i) Inter-turn and inter-coil insulation shall be designed such that di-electric stress is
uniformly distributed throughout the windings under all operating conditions.
ii) The winding shall be provided with class F insulation or better (as applicable to
dry type transformer as per IS: 2026 part II). However, temperature rise in
winding and core shall be limited to class B insulation.

04. OFF CIRCUIT TAP SWITCH
i) Bolted link type within enclosure, with easy accessibility.
ii) Designed for sustained over current of at least 150% of the rated current of the
winding
iii) Capable of repeated operation and withstanding short circuit forces
iv) Tap position configuration diagram shall be provided.
v) Inspection/operation / or repair shall not require removal of transformer core
from its enclosure.
vi) Shall not occupy any intermediate position between clearly marked tap position.
05. TERMINATIONS
It shall be possible to withdraw the transformer easily after disconnecting the
connections without disturbing the cable terminations. Cable termination box shall be
bolted type and supported from bottom so that after withdrawing the transformer, it
remains at its same position.
Winding shall be brought out and terminated on external /cable boxes as specified in
the Technical Particulars.
i) Cable termination
a) Air insulated cable end box suitable for the type and number of cables
specified.
b) Air insulated disconnection chamber with inspection opening
c) Compression type brass cable glands with finned copper lugs of non
soldering crimped type.
d) Bolted type gland plated ( non magnetic material wherever specified).
e) Sealing kits with associated accessories like stress reliving , insulating
type, bi-fercating boot, HT insulating tape etc.
ii) Bus duct termination

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a) When bus duct termination is specified, flanged throat shall be provided to
suit the bus duct. Flange ends and inspection openings shall have
weather proof gaskets.
06. Bushings
i) Conforming to IS 3347 part-1,2 & 3 1979, Part 3&4-1988 and IS:2099-1986
for HT and IS 7421 for LT system.
ii) Minimum rated current of line end bushings shall be 1.5 times rated current of
the corresponding windings.
iii) Clamps and fittings made of steel or malleable iron shall be hot dip galvanized.
iv) Bushings rated 400 amps and above shall have non- magnetic clamps and
fittings only.
v) Bushing shall be solid porcelain type.
vi) Neutral bushings shall be provided as required for earthing of neutral point.
This shall be connected to brass/tinned copper bar and brought to outside the
body through porcelain insulator.
.07 NEUTRAL CURRENT TRANSFORMERS
i) Removable at site without opening transformer enclosure cover/active part.
ii) Secondary leads shall be brought to a weatherproof terminal box and from
there to the Marshalling box with 4 sq.mm copper armoured cable.

.08 WINDING TEMPERATURE INDICATOR
i) Local winding temperature indicator (WTI) shall have a 150-mm diameter dial
type indicator with a manual reset maximum reading pointer. There shall be
two potential free contacts for alarm and trip signals. The settings for
closing/opening of each contact shall be independently adjustable. Contact
rating at DC11, 110V DC shall be minimum 5 Amps. The device shall be
complete with lamp temperature sensing element, image coil, calibration
device, aux. CTs etc. as required and shall be operated by RTD element.
ii) Temperature indicator dials shall have linear gradations to clearly read atleast
every 2C. Accuracy shall be better than 1.5%.
.09 MARSHALLING BOX
i) All outgoing connections from the transformer viz temperature indicators, level
indicators CT secondaries, fault contacts for annunciation, etc. shall be wired
to a Marshalling Box.
ii) Degree of protection of enclosure shall be IP52 for indoor and IP55 for outdoor
type respectively.

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.10 RATING PLATE
Each transformer shall be provided with a rating plate giving the details as per IS:2026
(Part-I). The marking shall be indelible and the rating plate shall be located on the front
side. Exact value of transformer % impedance, as determined by tests shall be
engraved on it and also on the final submission of name plate drawing.
.11 NOISE
Noise level shall be low and shall be within limit depending on the rating of the
transformer as per IEEE-141.
.12 Earthing
i) All metal parts of the transformer with the exception of individual core lamination
core bolts and clamping plates shall be maintained of fixed by earthing.
ii) Two nos. of tinned copper earthing terminals shall be provided.
iii) One end of bushing CTs shall be earthed.
.13 List of Fittings and Accessories
i) Off-circuit tap switch as specified.
ii) Dial type winding temperature indicators operated by RTD elements.
iii) Bushing CTs as specified.
iv) Bi-directional rollers/flanged wheels with loading arrangement.
v) Lifting lugs and jacking pads
vi) Rating and diagram plates.
vii) Earthing terminals.
viii) Inspection cover
ix) Identification plate
x) Pockets for thermometer for winding temperature indicator.
xi) HV, LV and Neutral bushings
xii) Marshalling box.

.4 TESTS
The equipment shall be subjected to all the routine tests at the manufacturer works in
accordance with latest version of IS2026 Part I and III or, the relevant IPSS (where
specified), in presence of purchaser or his representative.

Test of all equipment shall be conducted as per latest BIS. Test shall also confirm to
International Standards IEC/VDE/DIN/BS.

The tenderer shall submit type test certificates for similar equipment supplied by him
elsewhere. In case type test certificates for similar equipment is not available, the same

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shall be conducted in presence of Purchaser or his representative if Purchaser so
desires, without any financial implications to purchaser.

The transformer should pass the non-hygroscopic test according to DIN VDE-0532 and
confirm to class E2 to prevent formation of moisture creepage path and resulting in
failure of transformer.

The transformer should withstand the extreme load variation without any cracking of
the casting. For this test certificate according to DIN VDE 0532 is to be furnished.

All the equipment shall be tested at site to know their condition and to prove suitability
for required performance. The site tests and acceptance tests to be performed by
manufacturer are detailed below.

The manufacturer shall be responsible for satisfactorily working of complete integrated
system and guaranteed performance.
Acceptance tests to be conducted at site :
i) Assembly inspection/ Painting check
ii) Measurement of winding resistance
iii) Measurement of voltage ratio and check of voltage vector relationship
iv) Measurement of no-load current.
v) Measurement of insulation resistance/ polarizatation index.
vi) Certification for on-load/ off-load tap changer
vii) Final documentation check

.5 DRAWINGS & DOCUMENTS
The suppliers shall supply the following drawings / documents and manuals.
i) List of drawings
a) Overall General arrangement drawing
b) Rating and diagram plate
c) GA of Marshalling box
d) Wiring drawing of Marshalling box
e) H.V. cable box assembly
f) L.V. busduct assembly
g) QAP, Internal Test Certificates and Inspection Certificates
ii) Instruction manuals for erection, testing and commissioning.
a) Instruction manual shall give step by step procedure for:
- Erection, testing and commissioning
- Operation
- Maintenance and
- Repair
b) Operation and Maintenance Manual

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc JU o 2U5
- Recommended procedure for routine maintenance
- Tests for checking of proper functioning
- Diagnostic trouble shooting/ fault location charts
c) Storage, conservation and re-commissioning Manual
d) Safety Manual

Note : - Instruction manuals shall contain:

a) Manufacturers catalogues with ordering specification for all items
b) List of consumables with specifications, brand names and annual
consumption figures
c) Procedure for ordering spares.
d) Drawings relevant for erection, operation, maintenance and repair of the
equipments.

iii) List of special tools and tackles

.6 TECHNICAL PARTICULARS

Sl.
No.
Particulars

1000/ 2000 kVA
1. Specification IS 2026,
Part I - 1977
Part II - 1977
Part III - 1981
Part IV - 1977
IS 11171 - 1985
2.
Type
Three phase, core type, cast
resin dry type
3. Duty Indoor, installed in room
4. Degree of Protection of Enclosure
IP42 for indoor and
IP45 for outdoor.
5. Voltage HV/LV 6.6 or11 / 0.433 kV
6. Frequency 50 Hz
7. No. of phase 3
8. Continuous rating 1000/2000 kVA
9. Conductor Copper
10. Insulation class Class F or better
11. Cooling AN
12. Winding connection Delta / Star
13. Vector group DYn 11

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Sl.
No.
Particulars

1000/ 2000 kVA
14. Neutral grounding Effectively earthed
HV Unearthed 15.
System earthing
LV Effectively earthed
16. Percentage impedance 5% or 6.25% (as applicable)
HV
Cable end box suitable for
termination of XLPE aluminium
cables, with air insulated
disconnecting chamber
17.
Termination
LV

Suitable for termination of
Busduct with disconnecting
chamber
Temperature rise over 50C ambient temp
a) In winding (measured by Resistance method) 80C
b) Core and other adjacent parts of winding 80C
18.
c) Core and other parts not adjacent of windings
Within safe limit of core and
adjacent materials.
Bushing mounted CTs 19.
CT in LV Neutral bushing for standby E/F
protection
Ratio : 500/5 A
Class : 10P15
Off circuit tap changer Bolted Link type
a) Range 5%
b) Total tap positions 5
c) Taps above nominal voltage 2
d) Taps below nominal voltage 2
e) Voltage per step variation 2.5 %
20.
f) Tap change controls Manual
21. Impulse test withstand voltage As per IS 2026, Part III 1981
22. One minute dry and wet power frequency
withstand voltage
- do -
23. Short circuit level on HV side 40 kA for 3 Seconds
24. Time duration to withstand 3 phase short circuit
at secondary terminals, without any injury.
5 Secs.
25. Auxiliary supply voltage 240 V AC
26. Parallel operation Suitable for parallel operation
with transformers of similar
ratings
27. Overload capacity As per IS 6600 1972
28. Paint & Paint shade Epoxy based (Shade 632 as

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Sl.
No.
Particulars

1000/ 2000 kVA
per IS 5)

1.02.02 VCB (Transformer Isolation)

1.02.02.01 6.6/ 11 kV CIRCUIT BREAKER (WITHOUT PROTECTION &
METERING) PANEL
The 6.6/ 11kV circuit breaker panel shall be totally enclosed dust and vermin
proof, sheet metal clad, floor mounted, free standing, indoor type and shall
house circuit breakers, bus bars, control equipment, heat shrinkable cable
termination, current transformers, potential transformers, instruments, relays,
annunciation system and other accessories. This factory assembled HT circuit
breaker panel shall be with fully draw out type breaker carriage,
compartmentalised design with pressed sheet steel (thickness not less than 2.0
mm) and with IP-4X class of enclosure. All doors other than cable chamber
shall be of hinged and lockable type with neoprene gaskets at all joints and the
cable chamber shall be fixed with nuts and bolts. Additional wire mesh guards
and gaskets shall be provided for cable chamber. Two separate earthing
terminals shall be provided for HT panels. The HT panel shall be provided with
metallic automatic safety shutters or those made of fibre glass of suitable
insulation, which cover automatically the isolating contacts when circuit
breaker is withdrawn from service position. Ventilation openings shall be
provided where essential and shall have suitable screen protection.

Salient technical parameters to which the Circuit breaker panel shall conform
are as follows:
Service voltage 6.6/ 11 kV +6%, -9%
System Frequency 50 Hz +4%, -6%
Degree of enclosure protection IP 4X
Fault level in MVA 450/ 750MVA for 3 seconds
Type of CB Sulpher hexa fluoride (SF6)/
Vacuum Circuit Breaker(VCB)
Rating 1250A
No. of poles 3

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc JJ o 2U5
No. of breaks/pole 1
Location Indoor, floor mounted
Nominal current rating of bus bars same as main bus bar rating of
existing HT switchboard
Permissible temp. rise over ambient
for switch board
45
o
C
Operating Mode Manual
Spring charging mechanism Manual
Cable termination Heat shrinkable termination kits
Connection of outgoing feeders Cable

.1 General Features of 6.6/ 11kV Circuit Breakers
1) 6.6/ 11kV circuit breakers envisaged in the specification shall be
designed to control and protect the power distribution system. The
circuit breaker shall conform to IS:13118-1991 and IEC publication 56.

2) The circuit breaker shall be maintenance free and shall have adequate
capacity, insulation and mechanical strength to withstand
a) In-rush magnetising currents of transformers
b) Starting currents of drives
c) Transient surges developed during various abnormal operating
conditions
d) All electrodynamic stresses developed during abnormalities like
faults in the system.
e) Frequent start/stop duty of the industrial load. Normally, 2 (two)
quick succession cold starts and one restart from hot condition or
3 starts per hour shall be considered for design duty.

3) Circuit breakers shall have three operational positions, such as "Service"
"Test" and "Draw-out" position. It will be possible to achieve all the
above three positions with cassettes front door closed. Mechanical
indicators for all three positions shall be provided. The circuit breakers
shall carry a single break per pole which shall be identical with the other
2 pole chambers of the breaker. Simultaneous closing of the three poles

BHILAI STEEL PLANT


of a breaker on a single closing command shall be ensured. All circuit
breakers shall preferably be interchangeable.

4) The 6.6/ 11kV breaker shall be provided with electrical and mechanical
trip free features and an emergency mechanical push to trip the breaker.
All the features of the equipment shall ensure complete safety of the
operation and shall be complete with approved safety devices to protect
against potential hazards to operating personnel or to the equipment
around. The design shall include all reasonable precautions and
provisions for the safety.

5) All 6.6/ 11kV breakers shall be provided with at least 4 potential free
Aux. contacts to be used by Employer for their interlocking/signaling
purposes. Contact arrangement may be 2 NO + 2 NC and these shall be
rated for 10 amp current duty on the control and auxiliary voltages (both
AC & DC). Further, the following features shall be ensured in each 6.6/
11kV breaker panel:
a) Control plugs provided shall be mounted in horizontal fashion.
b) Mini bus earthing with proper interlocks.
c) All supporting insulators shall have increased creepage distance
as per IS and shall suit highly polluted atmosphere of steel
industry.

.2 Bus Bars
1) The Power Bus Bars of 6.6/ 11kV breaker panel shall be made of high
conductivity, electrolytic copper of purity 99.9% as per IS:613-1984 in
rectangular sections.
2) Horizontal and vertical bus bar shall be designed manufactured and
supported to withstand thermal and dynamic stress corresponding to
rated short time and peak withstand current as specified above.
3) Bus bar arrangement shall be as per IS:5578-1985 & IS:11353-1995.
Bus bar shall be sleeved with proper grade of insulating sleeves and of
proper colour code for each phase. Care shall be taken to obviate corona
formation at the joints and connections. All joints and connecting
terminals shall be tinned.

BHILAI STEEL PLANT


4) Bus bar shall be housed in a separate bus bar chamber with adequate air
clearance and bushing. The insulators/ bushing shall be cast resin type to
offer higher mechanical strength, during short circuit fault.
5) The clearance between bus bars shall be maintained as per standard. The
bus bar chamber shall be provided with detachable side covers for
regular maintenance and inspection and have provision of extension on
both sides.
.3 Cable Chambers
The cable end termination chamber for each panel shall have adequate space for
the termination of required number, type and size of cables and shall be
provided with suitable bracings to support the weight of the cables without
undue stress on the terminals. These chambers shall be complete with all
accessories and shall form integral part of the cubicle and shall be freely
accessible for cable connection.

.4 Earthing of 6.6/ 11kV Breaker panel
The following norms shall be adopted for earthing of HT breaker panel :
1) The 6.6/ 11kV outgoing cable shall be accessible to provide external
earthing on opening the backside lower cover of the panel.
2) Continuous copper earth bus bar shall be provided. However, the cross
section shall be checked to carry the peak short circuit and short time
fault current of the system.
3) Earthing bus bar shall be positively connected/ welded with 6.6/ 11kV
breaker panel, individual functional units and non current carrying
metallic units.
4) Hinged door shall be earthed through stranded copper galvanized
earthing braid.

5) For positive earthing of withdrawable units, silver plated copper
strapping earthing contacts of "make before" / "break after" type shall be
used ensuring earth continuity from "service" to "test" position of draw-
out type breakers on both the sides.

1.02.03 415V Switchgear

1.02.03.01 General

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc Jb o 2U5
The 415V switchboard shall comprise air circuit breakers & shall be metal clad,
indoor type floor mounted(in fully drawout execution).Switchboard shall be in single
tier execution for incomers & buscouplers & two tiers for outgoing feeders.
Relative position of incomers shall be as per the equipment layout requirement.
Sheet steel shall be CRCA of minimum 2.0 mm thickness.
Circuit breaker shall be mounted on fully drawout truck with service, test and
isolated positions and complete with following safety interlocks and safety shutters
with padlock facility :
It shall not be possible to move the truck in or out of cubicle when the
breaker is closed.
CB compartment door shall be mechanically interlocked so that it will not be
possible to close the CB in plug position when the door is open.
It shall not be possible to push the truck in close position if either of the
safety shutter is not free and not in close position.
The position of various control switches, push buttons, levers etc. requiring manual
operation, shall be at a height not less than 450mm and shall not exceed 1850mm
from the finished floor level.
Name plate for each incoming bus coupler, and outgoing feeder at front and back,
both on the fixed portion of the panel.
All panels shall have space heater with switch and cubicle illumination lamp with
door switch
All breakers of similar rating shall be interchangeable.

1.02.03.02 Insulation Level
Rated insulation voltage 1100 V
One minute power frequency withstand voltage :
2.5 kV for power circuits
2 kV for control circuits
Clearance in air (minimum) :
Phase to phase - 25.4 mm
Phase to earth - 19.0 mm

1.02.03.03 Short Circuit Strength
Rated short time withstand current not less than the system short circuit level
specified for 1sec.
Rated peak withstand current not less than 2.1 times the system short circuit
level.

1.02.03.04 Busbars
Busbars made of EC grade aluminium alloy equivalent to E91E WP as per IS
5082, 1981, size adequate for specified rated continuous and SC current.
Jaw contact to be mounted on ACB and fixed contact to be mounted on the bus
side (as per the manufacturers standard).
Three phase, neutral (with atleast 50% rating of main buses) and continuous earth
bus. Bus bar shall be provided with proper grade & colour of heat shrinkable
sleeve.
Rating of horizontal buses shall be same as that of incomer circuit breakers and

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc J? o 2U5
vertical run shall be same as that of outgoing breaker rating
Temperature rise of bus bars shall not be more than 40 deg. C above an ambient
of 50 deg. C.

1.02.03.05 Protection Requirements
One auxiliary relay for each transformer incipient faults :
a) Buchholz - alarm (63X)
b) Oil temp. high alarm (490X)
c) Winding temperature high alarm (49 X)
d) Buchholz trip (63Y)
e) Oil temp. high - trip (490Y)
f) Winding temp. high trip (49Y)
For the above faults, contacts to be made available for inter tripping primary side
breaker also.
All other protections as specified.

1.02.03.06 Construction Features (Mechanical Design)
Sheet steel clad, floor mounted, free standing design, non-dust proof construction
Extension bus links properly spaced for terminating single cables of size 120
sq. mm and above as well as for terminating multiple cables of all sizes.
Where more than one cable have to be terminated per unit, the arrangement
shall permit connection and disconnection of individual cables separately
without disturbing other cables.
Double, compression type brass cable glands and crimping type, tinned, heavy
duty copper lugs suitable for the type, size and number of cables to be
terminated, to be supplied with the switchboard for all LT power and control
cables.
The interior of the switchboard shall be finished with OFF WHITE paint shade.
All the panels shall be of uniform depth.
All panels shall be supplied with base channels.
The enclosure class shall be IP52 or better.

1.02.03.07 Relays

Flush mounted
Mechanically operated flag indicators with all relays capable of being reset
without opening casing
Shall withstand impulse voltage in accordance with IS/IEC recommendation.
Test facility by plug from panel front.
CT secondary shall be shorted on relay withdrawal.
Diagram plate at the back of case to identify connections.
The relay shall be microprocessor based numerical and communicable type.

1.02.03.08 Circuit Breaker
01. Electrical Features
Air break triple pole (4 pole in case of DG power incomer) drawout type conforming
to IS 13947.
Identical tripping/closing coil rating shall be provided as per the suppliers standard.
Rated continuous current as specified.
Symmetrical breaking capacity and 1 second rating of the breaker not less than the
system short circuit level specified.
Making capacity 2.55 times breaking capacity.
Performance category : P2

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc JS o 2U5
Auxiliary contacts : 6 NO + 6 NC minimum, convertible from NO
to NC and vice versa at site.
Ratings :
Continuous 10 amps
AC 11 4 amps at 240 V
DC 11 0.5 amps at 110 V

02. Operating Mechanism
Manual or power operated mechanism as applicable
Spring charged stored energy mechanism to ensure high speed closing and
tripping independent of the operating forces.
Anti pumping and trip free feature
Emergency tripping by mechanically operated trip push button (shrouded to
prevent accidental closing) acting directly on the trip bar.
Closing operation of the breaker to charge the tripping spring, ready for tripping.
Mechanical indication to show :
Closing spring charged
Breaker ON/OFF/TRIP
Breaker to close only when spring fully charged
Non-reset type operation counter
For manually operated breakers.
Independent manual charging of closing spring and closing by handle.
Alternatively, closing by mechanical push button with spring previously charged
by handle.
For electrically operated breakers :
Charging of closing spring by motor
closing by closing coil
spring charging motor and closing coil suitable for rated control voltage (240
AC unless otherwise specified).
One opening and one closing operation without control supply.
Provision also for manual closing with spring charging motor automatically
decoupled as soon as charging handle is inserted.

03. Drawout Features
3 distinct positions viz. service, test, and isolated with the door closed.
Mechanical position indication and locking/latching facility for all 3 positions.
Power connections - self aligning, plug-in type.
Control connections - sliding or plug socket type, mechanically coded, to prevent
wrong insertion, continuous rating 16 amps minimum.
Automatic safety shutters to prevent accidental contact with live parts when the
breaker is withdrawn.

04. Safety Interlocks
It shall not be possible to close the breaker in any intermediate position other than
the 3 fixed positions.
With the breaker closed, it shall not be possible to rack it in from any of the 3
position to another.
Mechanical stopper to prevent accidental falling while withdrawing.
It shall not be possible to rack in the breaker from isolated to 'test' position with the
door open together with provision for defeat of this interlocking, however, it shall be
possible to close the door only when the breaker is brought back to 'isolated'
position.

BHILAI STEEL PLANT


It shall be possible to open the door only when
breaker is OFF and
is in 'Isolated' position.
Remote closing of breaker is not permitted with door open.
Insertion of breaker into 'Service' position shall not be possible if the shutters are
not free.

05. Internal Control Wiring
Control wiring by 1100V grade PVC insulated, single core copper conductor of
minimum cross section 2.5 sq. mm
Flexible wires, protected against mechanical damage for wiring to door-mounted
devices.
Wires identified at each end in accordance with schematic diagrams by interlocked
type ferrules.
Colour code for control wiring :

AC black Earth wire - Green
DC light grey Trip circuit - Red

All connections external to a feeder, all the auxiliary contacts of the LT breaker,
and all spare contacts of the relays shall be wired on to the terminal blocks.
Interconnection between panels of adjacent shipping sections to be brought out to
a separate terminal block, wires for interconnection properly labeled, looped and
bunched inside the panel for connection at site.
Not more than two connections shall be carried out on one terminal.

06 External Terminations
06.1 Control Terminations
650V grade multiway terminal blocks of non-tracking moulded plastic complete
with insulated barriers, stud type terminals, washers, nuts and lock nuts and
identification strips.
Power and control terminals segregated.
Control terminals of minimum rating 10 amps suitable to receive 2.5 sq. mm
copper conductor.
20% spare terminals in each control terminal block.
06.2 Power Terminations
Suitable for accepting cables/bus trunking as specified in the technical particulars.
All spare contacts wired upto terminal block of the panels
a) Protective relays - withdrawable type
b) auxiliary, timer relays - fixed type

07.0 Microprocessor based releases
07.01 General
The control unit shall be interchangeable on site for adaptation to changes in the
installation.
Sensors shall be non-magnetic or of the Rogosky type for accurate current
measurements.
The control unit shall measure the true RMS value of the current.
The control unit shall comprise a thermal memory to store temperature-rise data in
the event of repeated overloads or earth faults. It shall be possible to disable this
function if necessary.

BHILAI STEEL PLANT


07.02 Protection
The control unit shall offer the following protection functions as standard:
1. Long-time (LT) protection with an adjustable current setting and time delay;
2. Short-time (ST) protection with an adjustable pick-up and time delay;
3. Instantaneous (INST) protection with an adjustable pick-up and an OFF position.
4. Earth-fault protection with an adjustable pick-up and time delay.

Current and time-delay settings shall be indicated in amperes and seconds
respectively on a digital display. Acknowledgement that the setting change
should translate to the trip threshold.
07.03 Measurements
An ammeter with a digital display shall indicate the true RMS values of the currents
for each phase.
An LCD Screen should continuously display the most heavily loaded phase apart
from the load level on the three phases.
A maximeter shall store in memory and display the maximum current value
observed since the last reset. The data shall continue to be stored and displayed
even after opening of the circuit breaker.
The control unit shall measure voltages and calculate power and energy values.
These values shall be displayable on the screen and updated every second. The
minimum and maximum values shall be stored in memory.

.07.04 Communication
The circuit breaker shall be capable of communicating the following data through a
bus:
Circuit-breaker status (open/closed, connected/disconnected/test, tripped on a
fault, ready to close);
Control-unit settings, including protection setting parameters.
Tripping causes;
The measurements processed by the control unit: current, voltage, frequency &
power(active & reactive).
It shall be possible to remotely modify circuit-breaker settings:
Settings within the range defined by the switches on the front panel of the control
unit;
Settings of the protection functions and the alarms.
It shall be possible to remotely control the circuit breaker of identified
feeders only.(Viz. all incomers & buscouplers)
Communications functions shall be independent of the control unit.

08. Indicating Instruments(Analog Meters)
Taut band type
Size
Incomer and sectionalizer 144 sq. mm
Outgoing 96 sq. mm

Flush mounting : in front of the cubicle
Accuracy class - 1.0
Ammeters shall be compatible with CTs of 5A secondary and read actual currents.
For motor feeders ammeters shall have suppressed scale upto 6 times of full load
current after 1.2 times of full load current and shall have red mark on full load

BHILAI STEEL PLANT


value.

09. Protective Devices
All control circuits shall be individually fed by MCBs with built in thermal and magnetic
releases. HRC fuses shall be provided for protection of spring charged motors of
electrically operated breakers.

10. Contactors
Contactors shall break without damage 8 times rated current upto 100 amp rating and
6 times rated current for above 100 amp rating. Continuous current shall not exceed 2
amp and initial pick up shall be limited to 9 amp. Class of insulation shall be E or better.
Drop out voltage shall be 45-65% of rated voltage and pick up shall be 85-110%
contactor duty shall be AC3 unless otherwise specified in design parameters.

11. Annunciation Scheme
Shall be static type.
Hooter and bell shall be provided for trip & alarm indication respectively.
Number of points shall be as per list.
Shall have facilities for test, reset and accept.
Shall consists of annunciation windows, relay blocks warning bell, emergency
hooter, push buttons etc.
All windows shall have two bunch LED in parallel.
All accessories including actuator (if respective scheme is in Contractor's scope)
shall be provided.
Sequence of operation shall be as follows :

Description Audio Visual
On occurrence of fault ON Flashing
On accepting OFF Steady ON
On resetting (fault cleared) OFF OFF
On resetting (fault persists) OFF Steady ON

12. Control Supply
Suitable arrangement for 240V AC reliable control supply of adequate rating shall
be provided in each 415V switchboard.
Two 240V AC feeders shall be provided in each board for control and annunciation
purpose.
Shunt trip shall be suitable for operation on 240V AC.
Shall have supervision facility, alarm shall be provided for non availability of any
one of the control supply.
MCBs shall be provided on incoming sides of supplies.
Control buses of two sections shall be connected through sectionalising switch.
Indication lamps shall be connected to 240V AC supply.
Isolation arrangement shall be provided on each panel to facilitate fault location
and testing. Separate fuses shall be provided for spring charging motors, for
indication lamps and for closing/tripping circuits of each cubicle.

13. Inter Tripping
Provision shall be made for tripping of incomer LT breaker on tripping of upstream
HT breaker.
Provision for tripping of upstream HT breaker on fault tripping of LT incomer
breaker shall also be provided.

BHILAI STEEL PLANT


14. Indicating Lamps
i) LED cluster type.
ii)LEDs used shall be of the colour of the lamp.
iii)Color shall be as follows:

15.
C
o
n
trol and Selector Switches
Control switches for circuit breaker ON/OFF control 3 position spring return to
neutral with lost motion device and pistol grip handle.
Other control and selector switches - stay put type with wing type knobs.

16. Push Buttons
Contact Rating :
Continuous 10 amps
AC 11 1.5 amps at 240V
DC 11 0.5 amps at 110 V DC, L/R - 40 ms
Colour :
ON RED
OFF GREEN
ACCEPT BLUE
RESET BLACK
TEST YELLOW

17. Protective Earthing
Continuous earth bus of minimum size 50 x 6 mm copper or equivalent aluminium
/galvanized steel section, designed to carry the peak short circuit and short time
fault current as specified.
Provided at the bottom extending throughout the length of the board, bolted/brazed
to the frame work of each panel with an earthing terminal at each end, for
terminating external earth conductor.
Vertical earth bus for earthing individual functional units.
All non-current carrying metal work (including metallic cases of instruments and
other panel mounted components) effectively bonded to the earth bus.
Hinged doors earthed through flexible earthing braid.
Looping of earth connection, resulting in loss of earth connection to other devices,
when the loop is broken, not permitted.
Withdrawable units provided with self-aligning, spring loaded, silver plated copper
scrapping earth contacts of make before/break after type ensuring earth continuity
from service to the test position.

18. Breaker Handling Truck
One for each switchboard, for withdrawing the breakers from the switchboard.
Height of platform adjustable to suit the levels at which the breakers are mounted.
Adequate mechanical strength for handling the largest breaker.
Guide rails and stops.
Incomer shall have analog meter (96 x96 mm) to measure line voltage/ bus voltage
& current (New point)

ON : RED
OFF : GREEN
CIRCUIT HEALTHY : WHITE
FAULT/WARNING : AMBER
SPRING CHARGED : BLUE

BHILAI STEEL PLANT


19. Auto Changeover Scheme
Usually both the incomers shall be ON with bus-coupler in the OFF
condition.
In case of failure of one of the supply feeders (say by upstream fault), it will be
sensed by the under-voltage relay which in turn will trip the incoming breaker
after a pre-set time delay.
Through the normally closed auxiliary contacts of the tripped incoming
breakers, the bus-coupler breaker shall close provided the other section is
Healthy.
The automatic transfer scheme shall be such that the automatic closing of the
bus section can be done only once and in case the bus coupler breaker trips
during auto changeover, no further auto closing shall be permitted. Auto
changeover shall not take place if the incomer breaker trips on fault. The
restoration of power shall be manual.
The automatic transfer circuit shall be controlled through an auto manual
changeover switch.

20. Technical Particulars
LT Switchboard
Nominal system voltage 415 V
System earthing Neutral solidly earthed
Short time rating 50 KA for 1 Sec.
Making capacity 105 kA
Control supply 240V AC
Configuration As per IS
Colour code R Y B
Busbar rating 4000 A
Enclosure IP-4X or better
Circuit Breakers
Symmetrical breaking current 50 kA
Making capacity 105 kA
Short time rating (for 1 second) 50 kA
Rating for incomers and
buscouplers
4000A
Rating for outgoing To be decided by the tenderer
Closing mechanism
Incomer & bus sectionalizer Motor operated spring charged
stored energy type
Outgoing Independent manual
Tripping mechanism Shunt trip
Control supply 240 AC
No. of auxiliary contacts 6 NO + 6 NC for future use
Termination
Incomer Bus duct (top entry)
Outgoing Armoured aluminium cables
Finish paint Powder coated Brilliant green,
shade 221 as per IS-5
Feeder Arrangement
Incomer & buscoupler
(Mounted in single tier
arrangement)
Air circuit breakers

BHILAI STEEL PLANT


Outgoings
(Mounted in two tier arrangement)
Air circuit breakers
Feeder requirement

To be decided by the tenderer
Colour identification LT switchboard colour identification
shall be change from RYB to YGR

21. Schedule of Components

Type of Feeder Sl. No. Schedule of components equipment
specification B/C Incomer Out going
ACB Feeder
1. 415V,50kA air circuit breaker with: 1 1 -
- independent, motorized, spring
charged mechanism, with
electrical/manual ON/OFF control
mechanism

- shunt trip
- ON/OFF indicator
2. 415V,50kA air circuit breaker with:
- independent, manual, spring
charged mechanism.
-shunt trip
- mechanical ON/OFF indicator
- - 1
3. Microprocessor based intelligent type
direct acting O/C, S/C & E/F release
with measurement control & data
transfer facility.
1 1 -
4. Microprocessor based direct acting
O/C, S/C & E/F release with
measurement & data transfer features
without remote control facility.
- - 1
5. Control switch ON/OFF with spring
return to neutral
1 1 1
6. Multifunction meter 1 1 1
7. Current transformer, class 1.0 for
metering
3 3 3
8. Microprocessor based motor protection
relay
- - 1(for motor
feeders only)
9. ON/OFF/Trip on Fault/Trip circuit
healthy lamps
3 4 4
10. Auxiliary relays flag indication for
buchholz trip and alarm and oil
temperature trip and alarm signals and
winding temp. alarm and trip signals
- 6 -
11. Auto changeover scheme with under
voltage relay, check synchronization
relay, PT etc.
Between incomers & bus couplers
12. Set of relays, contactors, timers, etc.
for annunciation scheme
As per Requirement
13. Set of relays, contactors, timers for
auto changeover scheme
As per Requirement

BHILAI STEEL PLANT


Type of Feeder Sl. No. Schedule of components equipment
specification B/C Incomer Out going
ACB Feeder
14. Impulse switch for tripping 6.6 kV or
11kV breaker
- 1 -
15. Two position, two contacts stay put
switch with pistol grip handle for
closing permission of upstream 6.6 kV
or 11kV breaker
- 1 -
16. ON/OFF indication lamp for upstream
breaker.
- 2 -
17. Inter tripping push button to trip the
upstream breaker
- 1 -
18. Analog Voltmeter with selector switch 1 2 -
19. Analog Ammeter - 3 -

1.02.04 LT BUSDUCT

01. Electrical Design
i) Electric power supply (Unless otherwise specified) 415V, 3 phase, 50 Hz
system.
ii) Insulation level
Rated Voltage : 415 V
Rated insulation voltage : 1100V
One minute power frequency voltage : 2.5 kV
Clearance in air (minimum)
- Phase to phase (mm) : 25.4 mm
- Phase to earth (mm) : 19.0 mm
Neutral grounding : Solidly grounded
iii) Short circuit strength
Rated short time withstand current not less than the system short circuit level
specified for 1 Sec duration.
Rated peak withstand current not less than 2.1 times the system short circuit
level.
iv) Rated current
Rated continuous current as specified while in enclosure and at specified
ambient temperature with maximum temperature of bus bars limited to 90 deg.
C
Neutral bus where specified with rating not less than half the rating of phase
bus.

02. General Arrangement
Rectangular, non-segregated phase, totally enclosed type.
Comprising of following sections, as applicable, to make the installation complete
and to match with the terminal equipment :
Switchgear lead-in section with flexible hood.
Straight section in standard length
Matching section (length as required)
Transformer lead-in section
Corner sections (horizontal and vertical)
Phase cross-over section, if required, to match phase sequence of boards.
240V AC space heater to be provided at suitable intervals and wired to external

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terminal box with heat resistant cables.
Silica gel breathers at appropriate locations.
Horizontal bends to be avoided by positioning the switchboard incomers at
appropriate place.

03. Construction Details
Degree of protection for enclosure IP 52 or better for indoor installation, and IP55
for outdoor part.
Enclosure material : Aluminum sheet, as specified of minimum thickness 2.0 mm
for sheet steel & 2.5 mm for Aluminum.
Enclosure construction rectangular welded construction.
Maximum temperature of enclosure under rated operating conditions limited to 75
deg. C
Bolted covers with gaskets for easy inspection and access to insulators and bus
bar joints.
Gasketted (Neoprene) connections between adjacent sections of metallic
enclosure.
Rubber bellows at each end to take care of vibrations.
Provision for mounting on brackets.
Seal off bushings shall be provided for busduct with indoor & outdoor part.
The outdoor part shall be provided with sloping top.
Seal off bushings shall be provided for busduct with indoor & outdoor part.
Supply of painted MS supporting structures with necessary hardware shall be
included in the scope of supply.
Surface treatment.
Two coats of epoxy paint for outdoor and synthetic enamel paint for indoor
application, preceded by de-rusting, cleaning chemically, degreasing, pickling in
acid, cold rinsing, phosphating, passivating and spraying with two coats of zinc
oxide primer.
Shade of paint :
Interior : Black
Exterior : Light grey shade 631 of IS-5 (unless otherwise
specified) for outdoor part
Shade 632 of IS-5(unless otherwise specified)
for outdoor part.

04. Busbars and connections
Material EC grade aluminium alloy equivalent to E91E WP conforming to IS 5082,
1981;or high conductivity electrolytic grade copper as per IS-613, 1984.
Final operating temperature of both bus bars and joints under continuous operation
in enclosure limited to 90 deg. C by thermometer method.
Bus bar shall be as per IS-5082,IS-13947 & IS-5578..
Phase identification by colour at ends and at regular intervals.
Busbar joints of bolted type, with zinc bichromated high tensile steel bolts, nuts and
spring washers. Bus-bar joint shall be champhered as per the manufacturers
practice.
Busbar surfaces to be tinned at joints and coated with oxide inhibiting grease prior
to jointing.
Copper busbar surface should be tinned.
Flexible connections for termination on equipment.
Expansion joints on straight runs with joints staggered in adjacent phases.
Bimetallic joints for jointing between dissimilar metals.
Busbar support insulators of non-hygroscopic material, having high impact and

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di-electric strength, with an anti-tracking contour.

05. Protective earthing
Aluminium earth bus of size 50 x 10 mm running throughout the length of the
busduct, positively connected to the body of the busduct.
Provision at each end of busduct for terminating external earth conductor.

06. Technical particulars for Design

Sl. No. Particulars
1. Application Indoor
2. Rated system voltage 415 V
3. System earthing Solidly earthed
4. Rated continuous current as specified ambient
conditions ( in enclosure)
4000 A
5. Rated short time withstand current (kA.rms) and its
duration
50 kA for 1 Sec.
6. Rated peak withstand current (peak) 105 kA
7. Temp rise over ambient of 50 deg. C
- Busbars
- Enclosure

40 deg. C
25 deg.C
8. Busbar material Aluminium/
Copper
9. Neutral bus To be provided
10. Earth bus material Aluminium
11. Earth bus size 2 nos. 50 x 10
12. Supporting insulators SMC/ FRP
13. Busduct enclosure material Aluminium
14. Busduct enclosure material thickness 2.5 mm
15. Busduct support structure To be provided
16. Overall (approximate) length of busduct (to be
finalized, during detailing) including bends flanges
etc.
8 m per set
17. Type Phase non-
segregated type
18. Maximum voltage at which busduct can operate 1100V
19. One minute power frequency withstand voltage(kV) 2.5
20. End connections Copper flexibles
21. Clearance:
-Phase to phase
-Phase to earth

25.4 mm.
19 mm.
22. Accessories:
-Space heater with thermostat
-Silica gel breather
-Busbar support structure
To be provided
23. Enclosure Protection class IP-52
24. Paint-Shade
-Interior
-Exterior

Black
Shade 631 of IS:5

1.02.05 Power Distribution Board (PDB)
- 415V, 3 phase, 4 wire, 50 kA (short time rating for 1 sec.) indoor type.

BHILAI STEEL PLANT


- Board shall be single front, metal clad, front matched dust and vermin proof,
fully compartmentalized and extensible on both sides, IP51 type enclosure.
- Degree of protection for enclosure IP 52 or better for indoor installation, and
IP55 for outdoor part.
- Shall have base channel of size ISMC 75.
- Shall have isolated busbar chamber for main busbar at the top, running
through out the length of the board. Chamber shall have removable cover.
- Cable alley shall have sufficient space for aluminium power cables and bottom
cable chamber shall be left free completely isolated from the vertical busbars.
- Busbars shall have same cross section through out the length. Rating of the
neutral busbar shall be 50% of the main busbar. Earth bus bar shall run in
bottom chamber throughout the length of the panel.
- Shall have moulded case circuit breaker triple pole, air break type with
independent manual quick make and quick break type. MCCB shall be capable
of breaking rated current at .3 pf at rated voltage. MCCB shall withstand the
fault current envisaged for 415V system.
- All feeders shall have ON/OFF lamps and 96 sq.mm size ammeter.
- Incomers of board and outgoing shall be MCCBs with E/F protection .

1.02.06 MOTORS & FIELD DEVICES

01. Low voltage squirrel cage induction motors :

Sl.No. Parameters Description
1.0 Standard IPSS 1-03-001 / IS 325 / IEC 34 & IEC 72
2.0 Constructional Features
(i) Frame size & rating As per IS 325
(ii) Motor body Grey iron casting as per IS:210-1978
(iii) Motor Feet Integrally cast with the stator
(iv) Body Design - Prevent breakage or other failures due to
vibrations normally encountered in heavy
industries .
- Motors shall be of weather proof construction.
- Designed to operate in the humid air stream
- Drain plugs to be provided .
(v) Protection for Motor & Bearing IP - 55
(with canopy for motor if installed outdoor)
(vi) Shaft ends & Extension Cylindrical as per requirement
Proper drilling and tapping shall be provided for
mounting of tachos for speed feedback (if required )
Crane motor in 225 and above frame sizes shall have
tapered shaft (1:10) ( New point)

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(vii) Bearings - For motor of rating upto 5 kW, ball bearings shall
be used for both DE & NDE end.
- For ratings above 5 kW the DE end shall be
provided with roller bearing and NDE end shall be
provided with ball bearing.
- Bearings for motors shall be of C3 clearance .
- Bearings shall be suitable for running of motor in
either direction.
(viii) Hazardous Area safety design As per requirement
(ix) Canopy To be provided for all outdoor motors .
(x) Greasing point At DE & NDE sides .
(xi) Paint shade Light grey shade 631 as per IS:5 or RAL 7030 (grey).
(xii) Direction of Rotation For crane and mill duty motors : reversible
For general purpose continuous duty motor :
Bidirectional (New point)
3.0 Terminal box
(i) Location Location on top preferably
(ii) Suitability - 4 Core Aluminium Cable
- Extension shall be done to receive the aluminium
cables to avoid cramping of the cables in the
terminal box .
(iii) Rotation 4 X 90 deg.
(iv) Earthing stud Inside Terminal Block
4.0 Cooling - TEFC
- Effective irrespective of direction of rotation
5.0 Quality of operation
(i) Vibration intensity Shall be limited as per IS 12075-1986.
(ii) Noise level As per IS: 12065-1987
(iii) Balancing Motors shall be dynamically balanced with full key on
the shaft- end and fan
6.0 Electrical design
(i) Power Supply 415 V +10 & - 15%
50 Hz +/- 6%
3-phase, 4-wire AC
50 kA for 1 second, solidly earthed.
(ii) Starting DOL
(iii) Min Voltage for Start & Run 85 % of rated voltage at terminal
(iv) Starting Torque >= 160 % Rated Torque
(v) Breakdown or pullout torque Minimum 275 % of the rated torque
(vi) Starting current <= 600% Rated current
(vii) Duty S1/ or as specified in TS
For crane duty S5 40% with 150 start/hour.
For conveyor application S-3 and 6 starts / hr
For continuous duty- efficiency class EFF-1.
(viii) Starts/Hour permissible 3 equally spread or 2 in quick succession from cold or
one hot start, under rated load condition..
(ix) Max speed permissible 120% over speed for 2 minutes
(x) Overload capacity Capable of withstanding 60% Overload for 15 sec.
(xi) Efficiency All continuous duty motor (S1-100%) shall be of high

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efficiency confirming to eff2 class as per IEEMA-19-
2000 .
(xii) Derating Motor designed at 50 deg.C shall be derated suitably
for mentioned ambient temperature .
(xiii) Motor connections Motor with frame size 90 shall be connected in star
and of frame sizes more than 90 shall be connected in
delta .
For delta connected motors 6 leads shall be brought
out .
(xiv) Insulation Class F
(xv) Minimum Permissible
temperature rise
Limited to class 'B' (120 deg absolute)

(xvi) Torque Type Normal / High / High slip type / Stall Torque type
(as required for the specific application)
(xvii) Space Heater Out door motors above 45 kW
Indoor Motor above 110 kW
(xviii) No. of Poles 4 pole
(unless specific drive requirement or economics call
for other poles).
(xix) Testing As per approved QAP during engineering stage .
(xx) Mounting Normally horizontally foot mounting .
Other type of mounting as per specific requirement .

02. Low voltage slip ring induction motors (Only for cranes and mill duty) :-

1.0 Standard IPSS:1-03-001-92, IPSS 1.03-004-93 , IS 325 ,
IEC 34 & IEC 72
2.0 Application Slip ring induction motors shall be used only for
drives of charging cranes .
Slip ring motors shall be employed for intermittent duty
drives requiring frequent switching operations and
speed control and for heavy drive applications
requiring high starting torque and meeting frequent
overload conditions.
(i) Frame size & rating As per IS 325
Use of motors in frame sizes above 400 shall be
avoided on cranes .
(ii) Motor body Grey iron casting as per IS:210-1978
(iii) Motor Feet Integrally cast with the stator
(iv) Body Design - Prevent breakage or other failures due to
industries .
- Designed to operate in the humid air stream
- Drain plugs to be provided .
- All motors to have continuously rated slip rings.

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(v) Protection for Motor & Bearing IP55 degree of protection as per IS : 4691.

(vi) Shaft ends & Extension - Shall be of high grade steel .
- Cylindrical as per requirement
- Proper drilling and tapping shall be provided for
mounting of tachos for speed feedback (if
required ) in non drive end or shaft shall be
extended with different diameter and length .
Tapered shafts for all crane drive motors shall be
provided. Motors in 225 and above frame size shall
have tapered shaft (1:10) .
- Provision of double identical shaft extension
(cylindrical & taper) to be made (in case of
requirement for a particular application) .

(vii) Slip rings

All motors to have continuously rated slip rings.
Phosphor bronze or steel slip rings shall be
provided .Cast iron slip- rings shall not be used .
Brush holders shall be in a complete assembly
unit .
Slip ring unit shall have a cover with inspection
window .
For higher range of motors, separate disc is
provided between the slip ring and rotor
windings to prevent carbon dust ingression into
windings.
(viii) Bearings - For motor of rating upto 5 kW, ball bearings shall
be used for both DE & NDE end.
- For ratings above 5 kW the DE end shall be
provided with roller bearing and NDE end shall be
provided with ball bearing.
- Bearings for motors shall be of C3 clearance .
- Bearings shall be suitable for running of motor in
either direction.
(ix) Hazardous Area safety design As per requirement
(x) Canopy To be provided for all outdoor motors .
(xi) Greasing point At DE & NDE sides for online greasing facility without
dismantling the motor.
(xii) Paint shade Light grey shade 631 as per IS:5 or RAL 7030 (grey).
4.0 Terminal box
(i) Location On top preferably
(ii) Suitability - 4 Core Aluminium Cable
- Extension shall be done to receive the aluminium

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cables to avoid cramping of the cables in the
terminal box .
(iii) Rotation 4 X 90 deg.
(iv) Earthing stud One earthing stud shall be provided in the terminal box
and two terminals on mounting feet.
(v) Stator and rotor connections Separate and distinctly marked terminal box to be
provided for stator and rotor connections.
(vi) Protection class IP 55 in all the cases .
(vii) Cable glands Suitable for double compression type cable glands .
5.0 Cooling - TEFC design only
- Effective irrespective of direction of rotation
- The cooling code of motor is IC 411 as per IS :
6362.
(i) Vibration intensity Shall be limited as per IS 12075-1986.
(ii) Noise level As per IS: 12065-1987
(iii) Balancing Motors shall be dynamically balanced with full key on
the shaft- end and fan
(i) Power Supply 415 V +10 & - 15%
50 Hz +/- 6%
3-phase, 4-wire AC,
50 kA for 1 second, solidly earthed.
(ii) Starting DOL or thyristor converter (ASTAT or SIMOTRAS or
equv.) Soft starter feature through static voltage
control/VVVF as per application
(iii) Min Voltage for Start & Run 80 % of rated voltage at terminal
(iv) Breakdown or pullout torque Pull out torque of the intermittent duty motors to be not
less than 300% of the rated torque at 40% duty factor.
(vi) Starting current <= 600% Rated current
(vii) Duty Duty cycle shall not be less than S4-40% , with a
minimum of 150 starts per hour (600 starts / hour for
charging cranes and other process cranes) .
For conveyor application S-6 duty.
(viii) Starts/Hour permissibe Mechanically and electrically shall be suitable for
required number of switching / reversals or starts per
hour.
(ix) Max speed variation 250 % of rated synchronous speed at high
accelerating rates and rapid reversals .
(x) Max speed 250 % of rated speed or 2000 rpm whichever is less .
(xi) Rated synchronous speed Motors shall be of low synchronous speed for ease of
dynamic balancing of hoist rotating unit .
The motor speed preferably shall be as follows :
Upto 37 KW :- 1000 rpm
Above 37 KW upto 90 KW :- 750 rpm
Above 90 KW :- 600 rpm
(xii) Overload capacity 1.5 times the rated current for 2 minutes
(xiv) Void
(xvi) Derating Motor designed at 50 deg.C shall be derated suitably
for mentioned ambient temperature .
(xvii) Insulation Class H

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(xviii) Torque Type Normal / High / High slip type / Stall Torque type
(as required for the specific application)
(xix) Space Heater Out door motors above 45 kW
Indoor Motor above 110 kW
(xx) Over temperature detection and
protection.
Slip ring motors for essential drives to be provided with
Pt 100 resistance thermometers / thermocouples or
thermistors .
(xxi) No. of Poles Not applicable
(xxii) Testing As per approved QAP during engineering stage .
(xxiii) Mounting Normally horizontally foot mounting .
Other type of mounting as per specific requirement .
(xxiv) Derating Motors shall be derated considering all the factors
variation in voltage and frequency .
Ambient temperature
Thermal ability due to constant and variable
losses of the motor
Type of load driven

03. Roller Table Motors (Torque motors)

1.0 Standard IPSS 1-003-007-85
1.0 Duty & type All travel mechanism shall have roller table duty
motors .
2.0 Insulation class Class H insulation . temperature rise limited to class
F .
3.0 Maximum speed All roller table duty motors shall have a maximum
speed of 1000 RPM.
4.0 Cooling Shall be TENV type only .
IC 410 .
5.0 Temperature sensor Roller table motor (Torque motor) shall have built in
PTC thermistors .
6.0 Locked rotor withstand time Ability to withstand locked rotor conditions for
minimum 1 min. under hot conditions . The motors
shall meet the process requirement also.
7.0 Control system All the roller table motors shall be inverter duty in
case of VFD control otherwise RDOL .

04. High voltage squirrel cage induction motors

1.0 Standard IPSS 1-03-018/IS 325
i). Frame size & rating As per IS 325
ii) Stator Frame Fabricated Steel / High grade cast Iron
iii) Stator Core Laminated sheets of high grade low loss silicon steel

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iv) Motor body Grey iron casting as per IS:210-1978
v) Casing Feet Integral with the motor frame
vi) Body Design Prevent breakage or other failures due to vibrations
normally encountered in heavy industries
vii) Protection for Motor & Bearing IP 55 as per IS 4691-1985.
viii) Shaft Forged Steel shaft
ix) Bearings (below 1000kW ) Anti-friction Bearing with Regreasing facility & with
grease quantity controllers
Bearings
(1000kW & above)
- Pedestral type sleeve bearing with forced oil
lubrication. (Arrangements to be incorporated to
prevent lubricating oil from reaching the windings)
.
- Bearing temperature, lubricating oil temperature
and pressure to be measured and monitored .

x) Vibration monitor Shall be provided at the DE end of motor bearing
xi) Pedestals insulation Against circulating shaft currents
xii) Hazardous Area safety design NA / as specified
xiii) Indication of direction of
rotation
By Arrow blocks on non-driving end
xiv) RTD & BTD ( PT100 type) All motors shall be provided with Bearing (DE &
NDE) temperature detectors and 6 nos. stator
winding temperature detectors, RTDs for
monitoring alarm and trip conditions. RTD's shall
be of PT100 type (duplex).
Analog input cards shall be provided in PLC for
online monitoring of bearing (DE & NDE) and
winding temperature of HT motors above 1000
KW .
For HT motors, temperature of each RTD (for
winding / bearing) shall be wired to PLC system
and limit value contacts for alarm and tripping
shall be generated in the PLC along with the
display of all parameters of the motor including
the winding and bearing temperature.
xv) Vibration monitoring Vibration monitoring (online) shall be provided at
the DE end of motor bearing for motors of ratings
1000 kW and above and it should be connected
to PLC for online monitoring .
xvi) Paint shade Light grey , shade no. 631 as per IS 5
3.0 Terminal box
i) Protection IP - 55
ii) Type Phase segregated
iii) Location As per requirement
1 no. each on opposite sides of motor.
iv) Winding star point Winding star point shall be kept outside in the
motor for more than 200 KW HT motor and other

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important HT motor .
In case no differential protection is required, star
point of the winding may be formed inside the
neutral terminal box to be provided on one side of
the motor. The phase segregated terminal box
shall be placed on other side of the motor.
v) Suitability Termination of XLPE cables with heat shrinkable
cable end seals.
Each terminal box to have two inlets to
accommodate any parallel cables as required.
vi) Reversible To suit cable entry from Top / Bottom
vii) Earthing stud Inside TB for protective earth conductor termination
viii) No. of terminal boxes Separate for Space heaters, RTDs / BTDs , Vibration
monitor etc
ix) Fault withstand (Min.) Rated Short circuit level of the system voltage for
0.25 sec
4.0 Cooling TEFC / CACA / CACW
CACW system shall be complete with temperature
and pressure monitoring devices.
i) Vibration intensity Limited to 37.5 micron peak to peak.
ii) Noise level Continuous noise level should not exceed 85 db A at
a distance of 1.0 m from the motor body as per IS:
12065-1987.
iii) Balancing Dynamically balanced with full key on shaft end and
fan
i). Efficiency High efficiency design of 96% at Full load
ii) Starting DOL
iii) Min Voltage for Start & Run 80 % of rated voltage at terminal
iv) Starting Torque As specified in application
v) Starting current <= 600% Rated current
vi) Duty S1
vii) Starts permissible 3 successive start from cold condition OR 2
successive start from hot condition.
viii) Starts / hour 3 equally spread in normal Voltage, Frequency & Load
ix) Max speed permissible 150 % rated for 2 minutes
x) Differential protection Required for1000 kW & above
xi) Insulation Class F & confirming to IEC 34 - 15/1990
xii) Insulation Material Cast resin rich / VPI
xiii) Minimum Permissible
temperature rise
Limited to class 'B' (120 deg absolute)
xiv) Space Heater Required & automatically off during RUN
xv) No. of Poles 4 (or as mentioned specifically)
xvi) Locked rotor current withstand
time
5 sec longer than starting time under rated load
condition.
xvii) Surge protection As specified
xviii) Operational design Suitable to VCB Breaker
xix) Motor winding and inter turn
insulation, connections and
Shall be fully insulated using mica insulation. For such
motors surge absorbers (with non-linear resistance)

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leads: shall be provided within 10 to 15 meters from the
motor terminals to limit the over voltages.
OR
In case mica is not provided in motor insulation, both
surge capacitors and surge absorbers (with non-linear
resistance) shall be provided within 10 to 15 mtrs from
the motor terminals to limit the over voltages and rate
of rise of voltage.

05. Synchronous Motors
i). Frame size & rating As per IS 325
ii) Stator Frame Fabricated Steel / High grade cast Iron
iii) Stator Core Laminated sheets of high grade low loss silicon steel
iv) Motor body Grey iron casting as per IS:210-1978
v) Casing Feet Integral with the motor frame
vi) Body Design Prevent breakage or other failures due to vibrations
normally encountered in heavy industries
vii) Protection for Motor & Bearing IP 55 as per IS 4691-1985.
viii) Shaft Forged Steel shaft
ix) Bearings (below 1000kW ) Anti-friction Bearing with Regreasing facility & with
grease quantity controllers
Bearings
(1000kW & above)
- Pedestal type sleeve bearing with forced oil
lubrication. (Arrangements to be incorporated to
prevent lubricating oil from reaching the windings)
- Bearing temperature, lubricating oil temperature
and pressure to be measured and monitored .
x) Vibration monitor Shall be provided at the DE end of motor bearing
xi) Pedestals insulation Against circulating shaft currents
xii) Hazardous Area safety design NA / as specified
xiii) Indication of direction of
rotation
By Arrow blocks on non-driving end
xiv) RTD & BTD ( PT100 type) All motors shall be provided with Bearing (DE &
NDE) temperature detectors and 6 nos. stator
winding temperature detectors, RTDs for
monitoring alarm and trip conditions. RTD's shall
be of PT100 type (duplex).
Analog input cards shall be provided in PLC for
online monitoring of bearing (DE & NDE) and
winding temperature of HT motors above 1000
KW .
For HT motors, temperature of each RTD (for
winding / bearing) shall be wired to PLC system
and limit value contacts for alarm and tripping
shall be generated in the PLC along with the
display of all parameters of the motor including
the winding and bearing temperature.

BHILAI STEEL PLANT


xv) Vibration monitoring Vibration monitoring (online) shall be provided at
the DE end of motor bearing for motors of ratings
1000 kW and above and it should be connected
to PLC for online monitoring .
xvi) Paint shade Light grey , shade no. 631 as per IS 5
3.0 Terminal box
i) Protection IP - 55
ii) Type Phase segregated
iii) Location RHS viewed from DE / On top
01 nos. each on opposite sides of motor in case
of Differential Protection (or not) / Neutral TB
opposite to main TB
v) Suitability Termination of XLPE cables with heat shrinkable
cable end seals.
Each terminal box to have two inlets to
accommodate any parallel cables as required.
vi) Reversible To suit cable entry from Top / Bottom
vii) Earthing stud Inside TB for protective earth conductor termination
viii) No. of terminal boxes Separate for Space heaters, RTDs / BTDs , Vibration
monitor etc
ix) Fault withstand (Min.) Rated Short circuit level of the system voltage for
0.25 sec
4.0 Cooling TEFC / CACA / CACW
CACW system shall be complete with temperature
and pressure monitoring devices.
i) Vibration intensity Limited to 37.5 micron peak to peak.
ii) Noise level Continuous noise level should not exceed 85 db A at
a distance of 1.0 m from the motor body as per IS:
12065-1987.
iii) Balancing Dynamically balanced with full key on shaft end and
fan
2.0 Design Motors shall be of cylindrical design with brush less
excitation system and automatic voltage and power
factor regulation.
3.0 Power factor 0.9 or better.
4.0 Motor winding Motor stator winding braced for full voltage starting.
Squirrel cage type winding with short circuited rotor
bars for producing starting torque and accelerating
torque to bring the synchronous motor upto the speed
All the three windings stator , rotor and exciter shall
be VPI (Vacuum pressure impregnation) .
5.0 Bearings Small frame size motors shall have endshield
bearings and large motors shall have pedestral
bearings .

BHILAI STEEL PLANT


6.0 Cooling All the three modes of cooling arrangement as per
requirement
Open air (for the areas where air is relatively
clean e.g water supply pump houses)
Air to water (in closed cooling circuit)
Air to air cooling (ID fan etc.) . A shaft
mounted fan or a separate fan to be provided
for air circulation .
7.0 Excitation method Brushless excitation system (Integral exciter and
rotating rectifier assembly to eliminate the need for
brushes and slip rings both on exciter and motor
respectively) .
8.0 Automatic system power factor
correction.
Motor field to have micro processor based thyristor
controlled static excitation system (for automatic
system power factor correction).
9.0 Motor synchronism protection Field monitor relay to be provided for monitoring the
power factor of the system which in turn trips the
motor and the exciter field off if synchronism is not
achieved within a specific length of time or if the
motor pulls out of step .
10.0 Insulation class Class F insulation for field windings as well as for
stator with temperature rise limited to 70 deg. C (as
measured by resistance method) over an ambient of
50 deg. C.
11.0 Locked rotor withstand time Motors shall be capable of withstanding locked rotor
current for atleast 5 second longer than starting time
under rated load condition.
12.0 Starting method DOL / Auto transformer starting method / Load
commutated inverter (LCI)
13.0 Space Heater Space heater to be provided.

06. LT Inverter Duty Motor

Sl.No Parameters Description
1.0 Type - AC Squirrel cage induction motor.
- Inverter Duty
2.0 Standard - IPSS 1-03-001/ IS 325
- NEMA Standard MG1-1993 Part 31, or the latest
revision in so far as it is applicable.
A Frame size & rating - As per IS 325

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- 10:1 constant torque speed range motors may
exceed frame standard by one frame rating.
B Motor body Grey iron casting as per IS:210-1978
C Motor Feet Integrally cast with the stator
D Body Design - Prevent breakage or other failures due to
industries .
- Designed to operate in the humid air stream .
E Protection for Motor & Bearing IP - 55
F Motor Shaft Shall be provided with an external recessed slinger at
the drive end of the motor to provide additional
(minimum IP-54) protection from moisture and
foreign material.
G Shaft ends & Extension - Cylindrical as per requirement
- Shaft shall be extended for encoder / tacho.
mounting , accordingly suitable hole shall be
drilled and tapped .
H Internal Encoder Motors with speed variation of 1000:1 at constant
torque shall have internal builtin encoder for speed
feedback
I Bearing - Roller type bearing upto 5 kW .
- Ball Bearing at NDE end for above 5 kW .
- All motors shall have fully re-greasable, anti-
friction bearings.
- All motors shall have cast iron inner bearing caps.
- Bearings shall be oversized .
- All motors shall have a charged lubrication system
to inhibit moisture condensation.
- Standard motors shall have extended grease
fittings on the opposite drive-end to facilitate re-
lubrication. Grease ports shall be located on the
periphery of the motor endshield.
- Motor shall be fitted with a shaft slinger or V ring
seal on the drive end for a minimum of IP-54
protection (to help protection of bearing from
ingress of dust , dirt or fluids) .
J Hazardous Area safety design NA
4.0 Terminal box
A Location RHS viewed from DE / On top
B Suitability - 4 Core Aluminium Cable

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- The terminal box shall be oversize as compared to
NEMA requirements .
C Rotation 4 X 90 deg.
D Earthing stud Inside Terminal Block
E Miscellaneous - Shall be gasketed between the terminal box
halves.
- The conduit box shall be field convertible to cast
iron.
- External screws and bolts shall be grade five, hex
heads and be plated to resist corrosion.
5.0 Cooling - TEFC, Effective bi-directional
- TENV (for roller table duty)
- Motor with 1000:1 speed range and constant
torque shall have external fan .
- External fan motor shall be 3 phase , 415 V AC
- Thermistors shall be provided in the windings.
A Vibration intensity - Shall be limited as per IS 12075-1986.
- Shall not exceed .08 inches / second velocity.
B Noise level As per IS: 12065-1987
A Power Supply 415 V +10 & - 15% , 50 Hz +/- 6% , 4-wire AC, 50 kA
for 1 second, solidly earthed.
B Starting Variable Frequency Drive
C Service factor - 1.0 for VFD power .
- 1.15 for sine wave power .
D Peak transient voltage 1600 V
E Minimum rise time 0.1 microsecond
F Starting Torque 200 % rated torque for 1 minute below base speed
G Constant horsepower operation 1.5 times base speed .
H Duty Application dependent
I Max speed permissible 150 % rated for 2 minutes
J Derating for VFD As per above mentioned standard
K Insulation Class H limited to class F .
L Load Type Constant Torque / Variable Torque
(As per application)
M Space Heater - Out door motors above 45 kW
- Indoor Motor above 110 kW
N No. of Poles 4 / 6 / 8
8.0 Operating Characteristics
A Operation with variation in the Motors shall operate successfully under running

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voltage or the frequency conditions at rated load with variation in the voltage
or the frequency not exceeding the following
conditions:
+/-10% rated voltage at rated constant V/f ratio
except for specific torque boost situations.
Motors shall operate successfully under running
conditions at rated load and V/f ratio when the
voltage unbalance at the motor terminals does not
exceed one percent.
B Torques Motors shall meet or exceed the minimum locked
rotor (starting) and breakdown torques specified in
NEMA Standard MG1 Part 12 for Design B for the
rating specified when on sine wave power.
C Operating speed range - Zero to base speed in case of VT.
- 1000: 1 for CT (with blower cooling)
- 10:1 , 6:1 , 4:1 for CT .
D Locked rotor (starting) currents Shall not exceed NEMA Design B values for the
specified rating on 5:1 constant torque or less and
variable torque motors. NEMA Design A values are
allowed for 6:1 constant torque or higher value
constant torque rated motors.
Motors shall be capable of a 20 second stall at six
times full load current without injurious heating to
motor components.
E Efficiency - Shall have a nameplate minimum and nominal full
load efficiency for motors when tested in
accordance with NEMA standard MG1 Part 12,
IEEE Test Procedure 112 Method B, using
accuracy improvement by segregated loss
determination including stray load loss
measurements.
9.0 Motor location Outdoor / indoor installation .
1.0 Painting For indoor motors :
Total thickness of painting shall be 140 microns.
For outdoor motors:
Total thickness of painting shall be 240 microns.
11.0 Nameplate - Shall be of corrosion resistance stainless steel .
- In addition to standard nameplate information
following informations shall be included :
o Nominal efficiency .
o Bearing identification numbers.

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o Power factor.
o Torque values with speed range and amps for
that torque value.
o Full Load Slip RPM.
o Magnetizing amps
o Encoder PPR and Voltage rating (if included).

07. DC Electromagnetic brake

1.0 Standard Metric
2.0 Voltage 220V DC
3.0 Application Suitable for steel mill duty having long mechanical
life.
4.0 Duty Shunt brake for
- Continuous duty
- Intermittent duty
Series brake for
- One hour duty (mill duty)
- Half hour duty (crane duty)
5.0 Mounting Floor mounting, two shoes, self-aligning, quick
acting with self-lubricating robust bearings.
6.0 Brake shoe lining Lining of tough heat resistant material with
countersunk fixing rivets to prevent rubbing against
the brake wheel.
7.0 Shoe adjustment and
indications
Facility for brake torque adjustment
Lining wear indication
8.0 Coil Insulation : Class F
9.0 Braking Torque rating Minimum 150% of the motor FLT
10.0 Temperature limit for brake
magnet and brake drum
Brake magnet :
- The magnet shall not become heated , during
operation , to a temperature exceeding 150 deg. C
Brake drum :
- The temperature of the drum during working of
the brake shall not exceed 200 deg. C
11.0 Limit switch Limit switches to be provided for contact feedback
used for interlocking , indications etc.
12.0 Safety for fail safe operation Electrically released and spring applied for fail
safe operation (gravity operated counterweight
type are not acceptable)

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Manual / hand release shall be provided in case
of power failure or other failure in the system .
13.0 Maintainability of brake coil Brake coil connection brought to appropriate
terminal box for ease in maintenance and terminals
covered for protection against accidental touch.
14.0 Residual magnetic gap
adjustment
To increase the residual magnetic gap for reducing
brake application time anti magnetic shim shall be
provided .
15.0 Brake panel Necessary rectifier and brake forcing equipment
shall be included for DC electro-magnet brakes
used with AC system.
16.0 Installation of brake panel DC electromagnetic brake panel shall be installed in
MCC room

08. Field Switches

1.0 Enclosure protection All field switches to have enclosure class IP-65 in covered
area & IP-67 in open area.
2.0 Contacts Minimum separate contacts 2NO & 2NC for interlocks and
as required for process.(with external JB)

09. Power Resistance

1.0 Resistor design To meet arduous heavy duty industrial and steel works
application, unbreakable, rigid, resilient & rust less.
2.0 Material Fechral edge wound
3.0 Duty rating 10 minutes rating of BS: 587 and conforming to IPSS No. 1-
10-002-82 and addendum No 1 to IPSS (March 1985).
4.0 Construction Every turn of every grid is fully supported so that adjacent
turns and adjacent grids can neither vibrate nor distort so
as to make mutual contact.
The complete grid is spot welded to its neighbors thus
eliminating slacken support due to heating and cooling and
is mounted on mica insulated high tensile steel tie-rod and
mica creepage washers.
A tripping point is formed on each grid by a hole in the
welded portion which is double thickness and absolutely
flat.
All grids shall have either zinc alloyed or cadmium plated
surface for permanent weather proofing. Highest quality
mica and porcelain insulated terminals are to be used

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throughout.
The thermal loading of the resistance box should be
uniform.
5.0 Painting All metal works for the housing shall be degreased,
derusted and passivated before applying two coats of
stove enamel.
6.0 Terminals The terminals shall be easily accessible at the lower most
stack.
7.0 Enclosure class IP-30 or better for outdoor application and IP-11 for indoor
application
8.0 Testing Testing shall be carried in accordance to BS: 587.
9.0 Power resistors for
crane control
Shall be of Fechral edge wound resistance boxes .
The element design shall be either circular (Russian
design) or elliptical (BHEL design) .
Punched grid resistance boxes shall not be used for crane
control .

1.02.07 Individual Drive Control Level
01. Variable Frequency Drive (VFD)

1.0 Basic design particulars - Digital control technology with vector control (with /
without PG as per requirement) .
- IGBT based with sine coded PWM control.
- VFD shall communicate to basic automation system on
system communication bus .
- Suitable for variable torque or constant torque
applications requiring harmonic control as defined by
IEEE 519-1992.
- The drive shall have an internal EMC filter capable of
meeting the Second Environment levels for the EMC
directive without the need for additional components.
- Shall confirm to IEC 146 - International Electrical Code.
- For 4 quadrant operational drives , active front end type
VFD shall be provided .
- Where speed control I desired for production and quality
control VFD isto be provided .
- Where speed control is not required sof t starter or motor
intelligent controllers are to be provide.
2.0 Drive controller - Software configurable to either V/Hz (single or multi

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technology motor) mode or Sensorless Dynamic Torque Vector
mode (single motor).
- Full, closed loop flux vector control shall be available for
constant torque applications.
- Operating the drive with motor disconnected.
- Adjustable PWM carrier frequency within a range of 3
15 KHz.
- Suitable for use on both CT & VT loads.
- Multiple programmable stop modes including - Ramp,
Coast, DC-Brake, Ramp-to-Hold and S-curve.
- Multiple acceleration and deceleration rates.
3.0 Type of connection - Three full wave diode rectifiers supplied by phase shifted,
three phase AC to provide a fixed DC voltage.
- DC bus inductor on all ratings
- DC link capacitors
- Insulated Gate Bipolar Transistor (IGBT) power section,
shall be rated for variable / constant torque applications.
The power section shall use vector dispersal pulsewidth
modulated (PWM) IGBT gate control algorithm and soft
switching IGBTs to reduce motor terminal dv/dt and allow
longer cable length from drive to motor without output
filters.
- The Main Control Board shall be the same for all ratings
to optimize spare parts stocking and exchange
- Common control connection for all ratings.
4.0 Overload capacity - 110% of the rated current for 1 minute , 30 seconds at
150% (with inverse characteristics proportional to time)
for variable torque applications . Repetition interval shall
not be less than 9 minutes
- 150% of the rated current for 1 minute overload , 30
seconds at 200% (with inverse characteristics
proportional to time) and 200% of rated current for 0.5
sec. for constant torque applications . Repetition interval
shall not be less than 60 minutes .
5.0 Efficiency More than 97% or better at full speed and full load.
6.0 Input power supply - 415 V AC +10% & -15%
- 3 phase .
- 50 Hz + / - 6 %
- 4 wire neutral earthed system .
7.0 Voltage variation - Voltage variation of (+/-) 0.1 % with an input variation of
+10% - 15%.

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- Steady state regulation of (+/-) 0.25% guaranteed against
100 to 200 % load disturbance and + 6% & -6% input
supply frequency variation.
- The drive should be designed to operate on an AC supply,
which may contain line notching, and up to 10% harmonic
distortion.
8.0 Environmental conditions
8.1 Storage ambient
temperature range
Upto to 70 C (-40 to 158F).

8.2 Operating ambient
temperature range
without derating.
IP42 & above : 0 C to 50 C (0 to 122 F)
8.3 Relative humidity Upto 100% non-condensing.
8.4 Operating elevation Up to 1000 Meters (3,300ft) without derating.
8.5

Shock

15G peak for 11ms duration
8.6 Vibrations Suitable to withstand vibrations more than 0.5g.
9.0 Reference
9.1 Input reference voltage O +/- 10 V DC / 0 10 V DC / 4 20 mA .
9.2 Reference signals

The drive should be capable of the following speed reference
signals
Digital MOP
Jog
HIM (Program/Control panel)
Analog Input signals
Preset Speeds
Communication module commands
All reference signals may have a trim signal applied to them
for finer resolution and accuracy. Trim source and amount
should be programmable.
9.3 Loss of reference The drive should be capable of sensing the reference loss
conditions .
In the event of loss of an analog input reference signal, the
drive should be user programmable to the following
Fault the drive
Alarm and maintain last reference
Alarm and go to preset speed
Alarm and go to minimum speed
Alarm and go to maximum speed
Alarm and maintain last output frequency
Signal loss detection should be available regardless of the
function of the analog input.
10.0 Output
10.1 Output voltage From 0 to rated motor voltage .
10.2 Output frequency 0.5 - 400 Hz.
10.3 Output Waveform Sinusoidal

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10.4 Output frequency
resolution
0.01 Hz.
11.0 Reflected wave

Maximum of 3.15 times the bus voltage or 1600V, whichever
is less, up to cable lengths of 200 metres.
12.0 Starting torque 150 % / 0.3 Hz. (without PG)
150 % / 0 RPM (with PG)
13.0 Torque accuracy + / - 5 % .
14.0 Speed control accuracy + / - 0.02 % .
IR compensation to be provided for drive without PG .
15.0 Ramp rate - Linear acceleration and deceleration adjustable
independently from 0 to 3600 seconds .
- Provision of remotely selectable Accel / Decel settings
should be accessible through digital inputs also.
16.0 Main power
components in
incoming AC side
- ACB / MCCB with 50 KA rating
- Matching input isolation transformer / line reactor for
harmonic and noise suppression . For input isolation
transformer , the K factor shall be 4.0 or less.
- AC line surge suppression network .
- Input contactor .
17.0 Converter Inverter
Equipment
- Diode / Thyristor bridge for AC/DC.
- DC link circuit with reactor/capacitor
- IGBT bridge for Inverter for DC/AC.
- Harmonic transformer .
- Main PLC to take care of interlocking and sequencing etc.
- Mimic panel (where drive is HT)
18.0 Load side components - Filter network
- Electronic over-load relay for each motor (with display).
- Line contactors in output side (if required).
- Output reactor / terminator (if required)
19.0 Terminal blocks - Separate for control and power wiring.
- Power terminal blocks to withstand a minimum of 90 C
and marked for both inputs and outputs .
- Uniform color-coding to be followed for cabling, TB, etc.
20.0 By-pass Arrangement By-pass arrangement shall be provided to operate the motor
in case of failure of VFD.
21.0 Diode Bridge Minimum ratings of Diode cells.
- PIV rating : 2.5 times the peak value of line voltage
- dv/dt rating : 200V/microsecond for voltage control and
1000V/ microsec. for
inverter control.
- di/dt rating : 100A / microsecond.
22.0 Input / Outputs - Hard-Wired I/O

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Hardwired I/O should be provided via separate I/O cards
- Standard I/O Card
The Standard I/O board should consist of both digital
and analog I/O. It should be available in two versions;
one for 115/240 VAC digital I/O and one for 24V AC/DC
digital I/O.
- Analog I/O
Differentially isolated 10V (bi-polar) / 20mA analog
inputs .
- Digital Outputs
Relay outputs Minimum 04 nos.
Contact output ratings should be 240V AC / 24V DC,
Maximum 2.0 Amp
23.0 Protective features

AC line surge suppression network and overvoltage
protection .
- Under voltage in supply network
- Phase sequence protection and monitoring
- Single phase failure
- Motor loss
- Under voltage in DC bus
- Over voltage in DC bus
- Over speed protection in the event that the output
frequency exceeds the maximum reference by a specified
amount.
- Over load
- Earth fault
- Instantaneous over current
- Transformer fault ,If applicable
- Cooling fan failure
- Stall monitor for motor alarms
- Controlled shut down, when properly fused, with no
component failure in the event of an output phase to
phase or phase to ground short circuit and annunciation of
the fault condition.
24.0 Annunciations Following faults shall be annunciated in keypad of the drive /
HMI .
- AC line surge suppression network and overvoltage
protection .
- Under voltage in supply network
- Phase sequence protection and monitoring
- Under voltage in DC bus
- Over voltage in DC bus
- Over speed monitor
- Over load
- Earth fault

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- Instantaneous over current
- Transformer fault ,If applicable
- Cooling fan failure Stall monitor for motor alarms
- Motor fault (winding / bearing temperature, vibration) as
applicable
- Loss of frequency command
- Shall be able to store at least 16 previous faults in memory
on FIFO sequence .
In addition to annunciations in keypad , a separate
annunciation window shall be provided on front door of
the VFD panel .
25.0 Meters - Output voltmeter and ammeter with selector switches.
- Input volt meter and ammeter with selector switches .
- Output frequency meter (digital type).
- KW meter for drive ratings above 200 KW.
All digital display shall be programmable .
26.0 Other features
26.1 Bus Regulation

DC Bus regulation should be available to reduce the
possibility of drive overvoltage trips due to regenerative
conditions.
26.2 Load dependent current
limit

Programmable current limit from .1 amps to 150% of drive
rated amps. Current limit to be active for all drive states;
accelerating, constant speed and decelerating.
26.3 Dynamic Braking The drive shall have an internal, built in 7th IGBT for use as a
dynamic braking chopper. This IGBT shall have enough
capacity to handle greater than or equal to 100%
regeneration power from the output, continuously. The drive
shall also have a drive mounted dynamic braking resistor
for low level braking applications and interactive software to
protect the internally mounted resistor from abuse.
26.4 Fault Memory

16 nos. of faults to be stored on FIFO basis for fault analysis .
26.5 Ride Through

The control logic should be capable of "riding through" a
power outage of at least 0.5 seconds in duration. The inverter
section should be shut off after an 18% drop in bus voltage
to conserve power for the drive logic.
27.0 Selector switches - Local / Remote .
- Auto / Manual .
- Main / Bypass .
All the selector switches shall be of 10 A rating .
28.0 Pushbuttons - Trip reset .
- Start.

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- Emergency stop.
29.0 Lamps

- Drive ready .
- Drive trip .
- R , Y , B phase power ON .
- Control supply ON .
All the lamps shall be of cluster LED type having low voltage
glow protection..
30.0 Regulation & control
facilities
- Reference speed setter
- Ramp generator
- Speed feed back
- Current feed back
- Flying start
- Trigger module
- Pulse transformers
- Logic control module
- Sequence module
- PID control
- Zero speed / over speed monitor as applicable
- Momentary power loss restart .
- Auto tuning .
- Current limiter
- Skip Frequency
- Counter current / regenerative braking unit as applicable
- Active electronic components used shall be of industrial
grade hermetically sealed .
- Output signals for fault alarm , frequency arrival , running
signal .

32.0 Remote control facilities - Shall have transducer to monitor the outputs like motor
speed at remote place / HMI .
- Facility to accept speed reference from HMI / engineering
station.
33.0 Auto / Manual Mode

- The HIM should utilize the ALT function key to transfer
the drive from Automatic mode to Manual mode and
back.
- When in Auto mode, the drive to receive its frequency
command from the programmed source.
- When in Manual mode, control of the frequency
command to be transferred to the HIM speed control
keys (or potentiometer).
- The user should have the choice of preloading the HIM
with the current auto frequency reference before
transferring control to allow for smooth transitions
without speed jumps.

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34.0 Communication Bus RS485 (ModBus, ProfiBus-DP, DeviceNet) bus
Internally mounted interfaces shall be provided to connect to
different buses .
35.0 Test points

Two electronic test point parameters should be available to
examine data within the drive memory that is not available
through other parameters.
36.0 Operator panel Shall be mounted on the front door of the unit .
IP 66 protection class .
- All adjustments to be made with the door closed.
- Status and Power LEDs viewable through the cover
- Status LEDs for communications status, including
embedded DPI status, adapter health and
communications network status, viewable through the
cover .

37.0 Membrane keypad - The keypad shall be logically designed for two operating
areas with required number of keys.
- Local operator control like
- local start /stop ,
- jog forward / reverse .
- Programming .
Facility to run the drive without HIM shall be provided .
38.0 LCD display - Display shall be black lighted , enabling viewing in
extremes of lighting conditions
- Display shall be in alphanumeric (in English only)
- 21 characters , 7 lines .
- All the faults stored in memory shall be displayed by
scrolling .
39.0 Construction features - Floor mounted, free standing
- Dust and vermin proof
- Sheet steel clad
- Minimum 2.5 mm thick for panels.
- Minimum 2.0 mm thick for doors and side covers.
- Suitable to withstand vibrations to be encountered in steel
plant application.
- Cubicles with illumination lamps, door switches, space
heaters and adequate sockets for soldering.
- All control blocks plugin-type with necessary test sockets.
- Units shall be self contained and serviceable.
40.0 Enclosure and
ventilation
- Enclosure conforming to IP-42 or better with weather
proof enclosures
- Units shall be provided with cooling fans and louvers at the

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc ?2 o 2U5
bottom sides with filters.
All louvers shall have fine mesh filter behind them.
- Ventilation through individual ventilation ducts from
bottom not acceptable.
- For larger drives cooling fans of drives shall be powered
from different power source .

02. AC Line Reactor
1.0 No. of phases 03
2.0 Input power supply - 415 V AC + 10% & -15%
- 3 phase .
- 50 Hz + / - 6 % .
- 4 wire neutral earthed system .
3.0 Duty class T2 as per IEEE-1973
4.0 Overload - 125% for 2 hours
- 200% for 10 seconds
5.0 Standard IS: 5553 (Part-2)
6.0 Insulation class Class H
7.0 Impedance 3% / 5% (As per system calculation)
8.0 Maximum temperature
rise
95 Deg. C
9.0 Ambient temperature 50 deg. C
10.0 Location Normally in the drive panel (In a separate enclosure in case
of large size) .
11.0 Execution IP 21
12.0 Termination - Cables
- All termination should be brought out on 6 or 10 mm thick
fibre glass strip .
- Terminal description should be engraved on termination
strip
13.0 Cooling AN
14.0 Winding Material CRGO Si grade steel , Grade 51 or better
Construction Coils should be hot dipped and whole assembly should br
dipped in varnish.
Clamping stud should be insulated from lamination .
15.0 Rating Inductance : As per calculation
RMS current rating : As per calculation
Inductance : AS per calcualtion
16.0 Characteristic Reactors will be linear upto 200% of rated current .

03. Load Commutated Inverter (LCI)

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1.0 Standard IEC 146-1-2
2.0 Power System Input 3 Phase AC , +/- 10% of rated voltage
3.0 Input voltage dip 30 % of rated voltage without tripping
4.0 Frequency 50 Hz. , +/- 6%
5.0 Operating environment 50 deg. C , with 95 % RH non condensing
6.0 Type of motor to be
controlled
Synchronous motor
7.0 Efficiency More than 99%
8.0 Isolation transformer - Indoor installation
- Oil or dry type as per IEC 76-2
- Typical winding configuration :
6 pulse LCI : Delta-Wye
Pulse LCI :- Delta-Delta-Wye
- Taps : 2x2.5% above and below nominal voltage .
- Winding conductor : Copper
- Insulation class : Class H (In case of dry type)
9.0 Bridge device Thyristor
10.0 Configuration
(i) Source bridge AC fed 6 or 12 pulse SCR , regenerative with N+1 devices
(ii) Load bridge 6 or 12 pulse output configuration with with N+1 devices .
11.0 Output speed control
range
10 160% of rated speed .
12.0 Overload 150% overload for 1 minute / every 10 minutes (for CT loads)
110% overload for 1 minute / every 10 minutes (for VT loads)
13.0 Control Forced commutation below 10 % of rated speed .
Load commutated above 10 % of rated speed .
Torque regulated .
4 quadrant speed control .
Volt / Frequency control
Field excitation control
Programmable acceleration / deceleration ramps
14.0 Control accuracy Without tacho With tacho
(i) Speed regulation 0.1 % 0.005 %
(ii) Max. starting torque 0.75 PU 2.0 PU
(iii) Max. forward speed 1.0 PU 1.0 PU
(iv) Max. reverse speed 0.5 PU 1.0 PU
(v) Constant HP speed
range
Base to top Base to top
(vi) Constant torque speed
range
0.1 to base 1.5 Hz to base
15.0 Torque reversal
principal
DC link voltage reversal by firing of anti parallel thyristors in
the bridge .
No contactor is to provided for the same .
16.0 Protection Overcurrent
Overvoltage
Earthfault
Over temperature
Motor bearing and winding temperature measuring and
protection
17.0 Cooling Water cooled with deionized water
Redundant cooling pump with automatic control

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18.0 Auxiliary power supply 415 V AC , 3 phase , 50 Hz.
19.0 Reliability N+1 SCR redundancy (extra SCR in each bridge circuit) for
full power output even in the event of a device failure .
21.0 Loudness Less than 70 Db at 1 metre from enclosure
22.0 I/O Standard I/Os as per manufacturer .
In addition to standard I/Os , a dedicated PLC in the drive
panel for sequencing and interlocking of all the hardware
interlocks of the LCI .
23.0 Metering Analog meters mounted on drive panels .
For remote monitoring required transducers/ converters for
transmission of signals in HMI .
24.0 Feedback devices Encoder for position feedback
Tacho for speed feedback
25.0 Communication bus Profibus / Controlnet / Modbus compatibility.
In case of making compatible with PLC communication bus ,
required hardware and software to be provided .
26.0 Cable entry Top or bottom cable entry with no additional cubicle

1.02.08 INTELLIGENT TYPE MCC :-

A. General
1.0 Type Metal clad .
Non drawout type
2.0 Construction Modular construction .
Fully compartmentalized with metal / insulating material
partition.
3.0 Enclosure class IP52
IP 54 for non intelligent MCCs installed in non airconditioned
environment .
4.0 Type of execution

Single front.
5.0 Mounting Floor mounting.
Free standing with ISMC 75.
6.0 Installation Indoor.
B. Constructional Features :-
Sheet steel
Thickness 2.0 mm for load bearing members.
1.6 mm for non load bearing members.
1.0
Material CRCA
2.0 Cable entry Incomer :- Bottom cable entry.
Outgoing :- Bottom cable entry.
3.0 Design Separate cable alley.
Extendable at both ends.
Rear access through removable rear hinged cover door

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on one side and screwed at other side .
All the components shall be accessable from front .
Motor controller shall be flush mounted on the respective
door .
Interchangeable facility of same type of feeder modules
Each module to have covering at the bottom.
ACB cubicle door shall close when the ACB is in isolated
position.
4.0 Interlocking &
protection
Module door interlocked with main power isolating devices.
Power circuit isolation device to have pad locking in the OFF
position with door closed.
5.0 Operating height Minimum :- 300mm
Maximum :- 2000 mm.
6.0 Gland plate Undrilled removable bottom gland plates (3 mm thick)
7.0 Miscellaneous Neosprene rubber gasket shall be provided for all the doors ,
removable covers & between adjacent covers
Lifting hooks for all the shipping sections
Doors shall have concealed hinges .
8.0 Labelling Clear legible identification labels (anodized aluminium with
white letters engraved on black background ) with letter sizes
of :-
25-50 mm for MCC panel in front and back side of the panel .
5 mm for components and module name plates.
Danger board on front and rear sides in English , Hindi .
9.0 Earthing Two separate earthing terminals will be provided.
Bolted joints with tooth spring washers for good earth
continuity.
Earth bus to run in all cable alley of the panel .
10. Shipping length

To be limited to 2.4 M.
11. Limiting dimensions Width of MCC :- 800 mm
Width of Module :- 500 mm
Width of Cable alley :- 300 mm
Height of module :- 400 mm (min)
Depth of MCC :- 600 mm , maximum
However depth of incoming ACB panel will be 1200 mm
(minimum).
12. Paint shade Shade No. 631 as per IS-5:1992. or RAL 7035
13. Panel space heater In each panel with thermostat , MCB.
C. Busbars
(i) Main horizontal & vertical busbars

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc ?b o 2U5
1.0 Arrangement

Three phase & neutral.
2.0 Material High conductivity electrolytic aluminium alloy confirming to
grade E91E as per IS-5082 -1981.
3.0 Phase Busbar Rating Shall be able to carry continuously the connected load
(considering diversity factor) plus a 25% margin
Max. current density shall be :-
1.0 A/sq.mm for Aluminium
1.5 A/sq.mm for Copper .
4.0 Neutral Busbar Rating 50 % of phase busbar rating
5.0 Short circuit rating

50 kA for 1 sec.
6.0 Busbar configuration Red-yellow-blue from front to back or top to bottom or left to
right as viewed from front.
7.0 Busbar insulation Heat shrinkable PVC
R,Y,B coloured sleeves for phases
Black for neutral.
8.0 Busbar supporting
insulators
Non-hygroscopic
Flame retarded
Track resistant
High strength
Sheet moulded compound or equivalent polyster fibre glass
moulded type .
9.0 Max. temp. rise of bus

Not to exceed 40 deg. C. above ambient of 50 deg.C.
10. Air clearance for bare
busbar
Phase to phase :- 25.4 mm (minimum)
Phase to earth :- 19.0 mm (minimum)
11.0 Joints and tap off points Busbar joints and tap off points shall be shrouded and bolted
( with cadmium coated bolts with plain and spring washers
and locknuts).
Bimetallic connectors for connection between dissimilar
metals .
Antioxide grease for all bus connections .
12.0 Neutral bus isolation Through disconnecting link .
13.0 Vertical busbar Rear side
(ii) Earth bus
1.0 Material GI.
2.0 Size

Minimum 50 x 6 mm with extension at both ends .
(iii) Control bus
1.0 Material Copper.

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc ?? o 2U5
2.0 Size Minimum 25 x 3 mm .
(iv) Power supply bus for motor controller (from UPS)
1.0 Voltage 240 V AC , 50 Hz.
D. Insulation level
1.0 Rated insulation voltage

1100 V
2.0 Impulse withstand
voltage
4 kV as per IS-13947 (Part I) 1993
3.0 One minute power
frequency withstand
voltage
2.5 kV for power circuit & 500 V for control circuit
E. Pollution Degree
1.0 Pollution Degree Pollution Degree 3
As per IS-13947 (Part-1) : 1993 ;
unless otherwise stated
E Intelligent Controllers
1. Type Modular type
2. Wiring Contacts from components (breakers , contactors ,) shall be
hardwired to I/O terminal block of the controller.
All the potential transformer PT's , protection CT's (phase CT
and neutral CT) shall be hard wired directly to the controller or
the controller module shall have builtin CT and PT for
protection & metering purpose .
3. Power supply Separate power supply source (240 V AC ) from UPS through
MCB (for controller only).
Separate power supply for (interrogation voltage) from MCC
itself .
4. Inputs and outputs The controller shall have :-
Minimum 12 digital and 4 analog inputs
( For increasing the number of I/Os extended module can be
added) .
Minimum 4 relay outputs ( 240 V AC , 10 A ).
5. Functions in controller Protection
Control
Metering
Annunciations
9. Fault memory Faults to be stored in memory on FIFO sequence.
10. LED indications Controller healthy
Controller fault

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc ?S o 2U5
Controller power supply healthy
11. Communication Each motor controller (motor / feeder) unit shall communicate
on the communication bus (Devicenet / Modbus / Profibus)
with PLC directly or through Data concentrator / CN2DN
converter or any equivalent module / converter .
The communication protocol (bus) for intelligent MCC and
package PLC shall be same for ease of communication .
12. Communication Port 2 nos. RS 485 serial port
13. Communication
configuration
Trunk line configuration ( with dual redundancy) in horizontal
wireways.
Dropline configuration (with dual redundancy) in vertical
wireways .
Each Data concentrator / CN2DN converter or equivalent
module shall communicate with PLC on higher level
communication bus e.g Controlnet / Profibus / Modbus etc .
14. Communication speed 9.6 Kbps minimum (100 m distance)
15. No. of nodes (without
repeaters)
Minimum 32 nos.
16. Control From 16 character keypad and backlit LCD alphanumeric
display provided on the controller.
From HMI (located in control room).
The keypad shall have the facility to start and stop the motor
through a separate key (touch screen type) or separate PBs
are to be provided for the same on the front door of the
module .
17. Software All the configuration and monitoring shall be done through
inbuilt software .
All the required software required for operation and
communication shall be provided with latest version available.
F. Feeder arrangement
Incomers and Buscoupler
1.0 Isolating Equipment

3 pole manual ACB
4 pole manual ACB (for DG source as second Incomer)
Both the Incomers and Buscoupler shall be drawout type .
2.0 Quantity Two incomer
3.0 Bus coupler

Required.
4.0 Interlocking Required.
Normally only one Incomer shall be ON . After incoming
power failure of any Incomer or ACB trips , second Incomer
shall be made ON manually .

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5.0 Interlocking type

Electrically .
Mechanical (through castle key)
6.0 Indication Lamps LED cluster type indicating lamps for :-
MCCB / ACB ON/OFF/TRIP.
Power ON R / Y / B .
Lamps will be of M/S Binay optoelectronic make of 22.5 mm
dia.in all cases . However model shall be freezed during
detailed engineering .
7.0 Meters and selector
switches
96 sq.mm size voltmeter with 7 position selector switches
96 sq.mm size ammeter with 4 position selector switches
8.0 Current transformer 3 numbers for protection .
3 numbers for metering .
1 number neutral CT .
I number interposing CT (if required)
9.0 Potential transformer 1 number
10.0 Relays (mounted in
each ACB)
Microprocessor based relay with
O/L
S/C
E/F
protections .
The relays shall have communication facility with PLC on
communication bus.
F. Outgoing feeder arrangements
(i) Motor Starter feeders
1.0 Circuit breaker Three pole MCCB .
Three pole ACB (for rating above 630 A) .
2.0 Power contactor AC3/AC4 as per requirement.
3 pole.
Minimum 32 A at AC-3 duty.
Contactor coil rating for 240 V AC .
2NO + 2NC auxiliary contacts.
Mechanically interlocked for reversible drives.
3.0 Auxiliary contactors Required nos. as per scheme.
4.0 Control supply isolation
device
MCB
5.0 Test PB Inside module for testing of power contactor when the module
incoming power breaker is OFF
6.0 Space heater power
provision
For motor feeders of 45 KW and above :-
Through separate MCB and interlock with main power
contactor .
7.0 Ammeter in LCS Interposing CT shall be provided in the feeder module for

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc SU o 2U5
motor rating 37 KW and above.
8.0 Thermal overload relay
(for non intelligent
MCCs)
Electronic type (with indication for motors of rating 37 KW and
above)
9.0 Motor controller
A. Protections Thermal overload
Adjustable overload prealarm
Earth fault
Stalling
Unbalance
Short circuit
Single phase prevention
Under current
Too many starts
Under voltage
Under voltage lockout
Breaker or contactor failure alarm
Trip failure alarm
Over temperature
Winding and bearing temperature (for motor of rating 160 KW
and above).
B. Display data Voltage
Frequency
Power factors
Power consumption , KW
Thermal capacity
Temperature
Phase and average Amp.
Earth fault current
% motor load
% unbalance
Peak current during starting
Starting time
Pre trip values
C. Fault / alarm history
description
No. of trips
No. of operations ( Forward / reverse)
Hours run
Hours run last start
Kilowatt hours
Kilowatt peak demand
Alarm / trip history (with date and time)

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc Sl o 2U5
Alarm / trip description
Reference start curve (in graphics)
Start curve (in graphics)
Time to trip / reset
(ii) Power supply feeders
1.0 Circuit breaker Three pole MCCB.
Three pole ACB (for rating above 630 A) .
2.0 Indications ON/OFF/TRIP indication lamp.
3.0 Earth fault protection
required
Yes
G. Panel wiring
1.0 Power / current
transformer circuit
1.1kV grade single core , black colour PVC insulated ,
stranded copper conductor of minimum size 2.5 sq.mm.
For feeder rating 100A and above all the power circuit shall
be through rigid busbar .
2.0 Control and potential
circuit
1.1kV grade single core
Black colour PVC insulated
Stranded copper conductor of minimum size 1.5 sq.mm.
3.0 Ferrules Numbered plastic/ceramic ferrules.
Self locking type.
4.0 Marking Wiring will be properly marked as per relevant IS.
5.0 Spare contacts All spare contacts of relays selector switches & contactors will
be wired upto the terminal block.
Each components shall have at least one potential free spare
contacts.
6.0 Terminals - Power & control terminals shall be segregated by
insulating material like hylam/bakelite sheet.
- Power terminals will be stud type.
- Control terminals will be ELMEX type suitable for
connecting two cores of 2.5 sq.mm wires.
- Minimum 20 % spare terminals will be provided.
- The minimum rating of control terminal shall be 10 Amps.
- Color coded wires, TBs of different voltage rating to be
provided .
7.0 Cable glands Double compression cable glands for receiving external
power and control cables
H. Control Supply
1.0 Control transformer 1 nos. of 415V/240V control transformer of minimum 2.5 KVA
in each section.
Secondary unearthed.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc S2 o 2U5
2.0 Input and output side
isolation device
Input side :- MCCB
Output side :- MCB
3.0 Control supply
changeover system
Control supply auto and manual changeover through
contactor logic and through selector switch respectively
(Sel.sw. shall have a contact rating of 25 A at 240 V AC)

1.02.09 STAND ALONE STARTER

A. General :-
1.0 Type - Metal clad .
- Non drawout type.
2.0 Construction - Modular construction .
- Fully compartmentalized with metal / insulating material
partition.
3.0 Enclosure class IP52.
4.0 Type of execution

Single front.
5.0 Mounting - Floor mounting.
- Free standing with ISMC 75.
Sheet steel
Thickness - 2 mm for load bearing members.
- 1.6 mm for non load bearing members.
1.0
Material CRCA
2.0 Cable entry - Incomer :- Bottom cable entry.
- Outgoing :- Bottom cable entry.
3.0 Design - Rear access through removable rear hinged cover door.
- All the components shall be accessable from front .
4.0 Interlocking &
protection
- Module door interlocked with main power isolating devices.
- Power circuit isolation device to have pad locking in the
OFF position with door closed.
5.0 Operating height - Minimum :- 300mm
- Maximum :- 2000 mm.
6.0 Gland plate Undrilled removable bottom gland plates
(3 mm thick)
7.0 Miscellaneous - Neosprene rubber gasket shall be provided for all the
doors , removable covers & between adjacent covers .
- Lifting hooks for the panel .
- Doors shall have concealed hinges .
8.0 Labelling Clear legible identification labels (anodized aluminium with
white letters engraved on black background ) with letter sizes
of :-
- 25-50 mm for panel .
- 5 mm for components and module name plates.
- Danger board on front and rear sides in English , Hindi and
local language .
9.0 Earthing - Two separate earthing terminals will be provided.
- Bolted joints with tooth spring washers for good earth
continuity.
10.0 Paint shade Shade No. 631 as per IS-5:1992 equv to RAL 7035 .

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc SJ o 2U5
11.0 Panel space heater In each panel with thermostat , MCB .
C. Busbars
1.0 Arrangement

Three phase & neutral.
2.0 Material High conductivity electrolytic aluminium alloy confirming to
grade E91E as per IS-5082 1981.
3.0 Phase Busbar Rating - Shall be able to carry continuously the connected load
(considering all derating factors) plus a 25% margin .
- Max. current density shall be
- 1.0 A/sq.mm for Aluminium
- 1.5 A/sq.mm for Copper .
5.0 Short circuit rating

50 KA for 1 sec.
6.0 Busbar configuration Red-yellow-blue from front to back or top to bottom or left to
right as viewed from front.
- R,Y,B coloured sleeves for phases
- Black for neutral.
insulators
- Non-hygroscopic
- Flame retarded
- Track resistant
- High strength
- Sheet moulded compound or equivalent polyster fibre
glass moulded type .
9.0 Max. temp. rise of bus

Not to exceed 35 deg. C. above ambient of 50 deg.C.
10.0 Air clearance for bare
busbar
11.0 Joints and tap off points - Busbar joints and tap off points shall be shrouded and
bolted ( with cadmium coated bolts with plain and spring
washers and locknuts).
- Bimetallic connectors for connection between dissimilar
metals .
- Antioxide grease for all bus connections .
13.0 Busbar access Rear side
(ii) Earth bus
1.0 Material GI.
2.0 Size

Minimum 50 x 6 mm with extension at both ends .
(iii) Control bus
D. Insulation level
1.0 Rated insulation voltage

1100 V
2.0 Impulse withstand
voltage
4 KV as per IS-13947 (Part I) 1993
frequency withstand
voltage
2.5 KV for power circuit & 500 V for control circuit
E. Pollution Degree

BHILAI STEEL PLANT


as per IS-13947 (Part-1) : 1993 ;
F . Components

3 pole MCCB (upto 630A)
2.0 Indication Lamps LED type indicating lamps for :-
- MCCB ON/OFF/TRIP.
- Power ON R / Y / B .

switches
- 96 sq.mm size voltmeter with 7 position selector switches
- 96 sq.mm size ammeter with 4 position selector switches

4.0 Power contactor - AC3 duty of rated capacity .

5.0 Intelligent motor
controller
- As defined in clause no. 1.02.08 .
6.0 Motor protection relay
(for non intelligent
panel)
- Microprocessor based.
- Suitable for 5A & 1A
- Protections
Short circuit
Overload
Earth fault
Stalling protection
Undervoltage
Overspeed
No.of starts per hour (cold & hot)
- Communication facility with PLC.
- Memory for
Storing fault history & trending

7.0 Auxiliary contactors - Shall be provided for logic operation and operating
sequence .
- Shall have minimum 2NO+2NC auxiliary contacts.
G. Panel Wiring
1.0 Power / current
transformer circuit
1.1Kv grade single core , black colour PVC insulated ,
1.0 Power / current
transformer circuit
2.0 Control and potential
circuit
- 1.1Kv grade single core
- Black colour PVC insulated
- Stranded copper conductor of minimum size 1.5 sq.mm.
3.0 Ferrules - Numbered plastic/ceramic ferrules.
- Self locking type.
4.0 Marking - Wiring will be properly marked as per relevant IS.
5.0 Spare contacts - All spare contacts of relays selector switches & contactors
will be wired upto the terminal block.
- Each components shall have at least one potential free
spare contacts.
insulating material like hylam / bakelite sheet.
- Power terminals shall be stud type.
- Control terminals shall be suitable for connecting two cores

BHILAI STEEL PLANT


of 2.5 sq.mm wires.
- Minimum 20 % spare terminals shall be provided.
- The minimum rating of control terminal shall be 10 Amps.
- Color coded wires, TBs of different voltage rating to be
provided .
I. Control Supply
1.0 Control transformer 1 nos. of 415V/240V control transformer of minimum 2.5 KVA
2.0 Input and output side
isolation device
Input side :- MCB
Output side :- MCB

1.02.10 SOFT STARTER :-
A. Design Criteria:-
1.0 Incoming supply voltage 415 V + 10 % & -15% ,
50 Hz. +/- 6 %, 3 phase
2.0 Control Supply 240 V AC through control transformer.
However there shall be provision of control supply of
110V/240 V AC through shorting links in control
supply power terminal blocks .
3.0 Output Full wave in line control
4.0 Device IGCT/IGBT/ /Fast acting switching semi conductor
device.
5.0 Acceleration Stepless
6.0 Pump control Starting :- 2 30 seconds
Stopping :- 2 120 seconds
7.0 Adjustable current limit 500 % of In .
8.0 Adjustments - Dwell time at current limit with ramp continuation
after acceleration .
- Acceleration time adjustable current limit
- Minimum voltage adjustment
- Voltage stability adjustment.
- Initial torque ramp time adjustment .
- Kick start
9.0 Overload tripping range 100 130 %
(as per manufacturers characteristic curve)
10.0 Overload capacity Continuous :- 115 %
60 seconds :- 250 %
30 seconds : - 300 %
05 seconds :- 450%
11.0 Other features - Shall have facility to run in energy saving mode
during light load operation of the drive

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc Sb o 2U5
- Shall have bypass mode . Motor can run in
bypass mode in DOL .
- Soft starter mode or bypass mode can be
selected through selector switch mounted on
front side of the panel .
- In auto mode soft starter shall start / stop after
getting command from PLC.
- Shall have the facility of kickstart .
- Shall be able to communicate to PLC on dual
redundant communication bus . Accordingly
suitable cards / modules shall be mounted .
12.0 Protections - Short circuit
- Overload .
- Under voltage protection
- Current monitoring in each phases
- Transient voltage suppressor (MOV)
- Heat sink overtemperature protection
- Over temperature switches on each pole.
- RC Snubber ckt.
- Semiconductor fuse to be provided before the
soft starter controller .
- Single phase protection
13.0 LED Indications - Power ON (green)
- RUN (amber)
- Fault (red)
- O/C trip (red)
- Phase loss trip (red)
- Auxiliary trip (red)
B. General :-
- Non drawout type.
- Fully compartmentalized with metal / insulating
material partition.
3.0 Enclosure class IP52.
4.0 Type of execution Single front.
C. Constructional Features :-
1.0 Sheet steel

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc S? o 2U5

Material CRCA
3.0 Design - Rear access through removable rear hinged
cover door.
- All the components shall be accessable from front
4.0 Interlocking & protection - Module door interlocked with main power isolating
devices.
- Power circuit isolation device to have pad locking
in the OFF position with door closed.
(3 mm thick)
7.0 Miscellaneous - Neosprene rubber gasket shall be provided for all
the doors , removable covers & between adjacent
covers .
8.0 Labelling - Clear legible identification labels (anodized
aluminium with white letters engraved on black
background ) with letter sizes of :-
25-50 mm for panel .
- Danger board on front and rear sides in English ,
Hindi and local language .
- Bolted joints with tooth spring washers for good
earth continuity.
10.0 Paint shade Shade No. 631 as per IS-5:1992./ RAL 7035
11.0 Panel space heater In each panel with thermostat , fuse , switch.
D. Busbars
1.0 Arrangement Three phase & neutral.
2.0 Material High conductivity electrolytic aluminium alloy
confirming to grade E91E as per IS-5082 1981.
3.0 Phase Busbar Rating Shall be able to carry continuously the connected
load (considering all derating factors) plus a 25%
margin .
Max. current density shall be

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc SS o 2U5
1.0 A/sq.mm for Aluminium
1.5 A/sq.mm for Copper .
5.0 Short circuit rating 50 KA for 1 sec.
6.0 Busbar configuration Red-yellow-blue from front to back or top to bottom
or left to right as viewed from front.
R,Y,B coloured sleeves for phases
Black for neutral.
8.0 Busbar supporting insulators Non-hygroscopic
Flame retarded
Track resistant
High strength
Sheet moulded compound or equivalent polyster
fibre glass moulded type .
9.0 Max. temp. rise of bus Not to exceed 35 deg. C. above ambient of 50
deg.C.
10.0 Air clearance for bare busbar Phase to phase :- 25.4 mm (minimum)
11.0 Joints and tap off points Busbar joints and tap off points shall be shrouded
and bolted ( with cadmium coated bolts with plain
and spring washers and locknuts).
Bimetallic connectors for connection between
dissimilar metals .
Antioxide grease for all bus connections .
13.0 Busbar access Rear side
(ii) Earth bus
1.0 Material GI.
2.0 Size Minimum 50 x 6 mm with extension at both ends .
(iii) Control bus
E. Insulation level
1.0 Rated insulation voltage 1100 V
2.0 Impulse withstand voltage 4 Kv as per IS-13947 (Part I) 1993
3.0 One minute power frequency
withstand voltage
2.5 Kv for power circuit & 500 V for control circuit
F. Pollution Degree
as per IS-13947 (Part-1) : 1993 ;

BHILAI STEEL PLANT


G . Components
1.0 Isolating Equipment 3 pole manual ACB
ACB ON/OFF/TRIP.
Incoming power R / Y / B .
Auto / Remote / Local .
Soft starter mode / bypass mode .
Motor ON / OFF / TRIP.

3.0 Meters and selector switches 96 sq.mm size voltmeter with 7 position selector
switches
96 sq.mm size ammeter with 4 position selector
switches
4.0 Power contactor AC3 duty of rated capacity .
5.0 Thermal overload relay Electronic type
CT operated
Shall be connected in bypass mode .
6.0 Auxiliary contactors Shall be provided for logic operation and operating
sequence .
Shall have minimum 2NO+2NC auxiliary contacts
suitable for 5A DC .
7.0 Door mounted operating devices Start / stop operating PB.
Reset PB.
Selector switches :-
Auto / Remote / Local .
Soft starter mode / bypass mode .
H. Panel Wiring
1.0 Power / current transformer circuit 1.1Kv grade single core , black colour PVC insulated
, stranded copper conductor of minimum size 2.5
sq.mm.
2.0 Control and potential circuit 1.1Kv grade single core
Black colour PVC insulated
Stranded copper conductor of minimum size 1.5
sq.mm.
3.0 Ferrules Numbered plastic/ceramic ferrules.
Self locking type.
4.0 Marking Wiring will be properly marked as per relevant IS.
5.0 Spare contacts All spare contacts of relays selector switches &
contactors will be wired upto the terminal block.
Each components shall have at least one potential

BHILAI STEEL PLANT


free spare contacts.
6.0 Terminals Power & control terminals shall be segregated by
All control field wiring terminals shall be front access
.
Power terminals shall be stud type.
Control terminals shall be suitable for connecting
two cores of 2.5 sq.mm wires.
Minimum 20 % spare terminals will be provided.
The minimum rating of control terminal shall be 10
Amps.
Color coded wires, TBs of different voltage rating to
be provided .
Uniform color-coding to be followed for cabling, TB,
etc.
7.0 Cable glands Double compression cable glands for receiving
external power and control cables
I. Control Supply
1.0 Control transformer 1 nos. of 415V/240 V control transformer of
minimum 2.5 KVA .
2.0 Input and output side isolation
device
Input side :- MCCB
Output side :- MCB

1.02.11 Specifications of major components
01. MOULDED CASE CIRCUIT BREAKER (MCCB)

1.0 Reference standard

IS : 13947 (Part-2) : 1993
2.0 Rated Current

As specified in SLD
3.0 MCCB for motor
feeders
MCCBs for motor feeders shall be motor protection type
conforming to type-2 co-ordination. (MCCB without overload
not available. EOCR is being used)
4.0 Short circuit rating 50 kA (Minimum) (Ics =Icu).
5.0 Service Short circuit
breaking capacity (Ics)
100% of rated ultimate short circuit breaking capacity (Icu)
6.0 Operating handle

Yes
7.0 Safety Door interlock Door interlock

BHILAI STEEL PLANT


Padlocking in ON/OFF position
8.0 Withstand capability

Rated short time with-stand current (Icw) will be 12 times
maximum rated operational current for 1 sec.
9.0 Utilisation category

AC23B
10.0 Electrical features

- S/C , O/C, E/F protection for power supply feeders &
crane trolley line feeder MCCBs.
- Features to minimise the let-through energy (I2t) in the
event of short circuit on load side.
- Complete with continuous electronic / microprocessor
based adjustable thermal and magnetic releases.
- MCCBs for motor feeders shall be of motor duty class
with magnetic trip only . Overload protection shall be
through electronic overload relays .
11.0 Auxiliary contacts 1 NO + 1 NC
Alarm contacts.
12.0 Miscellaneous Can be used in load side or line side vice versa.
Shunt trip coil .

02. AC CONTACTORS

1.0 Service Indoor within steel cubicle for maximum system voltage,
starting of motors and miscellaneous loads
2.0 Standard Shall conform to IS / IPSS
3.0 No. poles 3 pole air break .
4.0 Operating type Magnetic coil operated at 240 V AC.
No economy resistors.
Insulation for coils shall be class 'E' or better
5.0 Rating 32A (Minimum) , Rated for 125% of full load motor rated
current for DOL motor feeders and 150% of motor rated
current for RDOL motor feeders.
6.0 Interrupting capacity Ten times the rated current for rated size upto 100A and
eight times the rated current for larger sizes.
7.0 Duty According to IEC 158-1
- AC 1 duty :- Non inductive or slightly inductive loads .
- AC 2 duty :- Slip ring motors : starting , plugging
- AC 3 duty :- Squirrel cage motors : starting , switching off
motors during running
- AC4 duty :- Squirrel cage motors : Plugging , inching.
Derated AC4 ratings shall be selected for inching and
plugging operation of the drive (crane duty).

BHILAI STEEL PLANT


8.0 Utilisation category

AC23A for unidirectional motors
AC24A for bi-directional motors
9.0 Aux. contact
requirement
- Minimum 4 NO +4 NC contacts with minimum rating of
- 10A , 415 V.
- 2A , 220 V for rated duty DC-11.
- Shall have the facility of adding add-on contact blocks.
10.0 Closing (pick-up)

85% to 110%
11.0 Dropout Will not be higher than 75% and lower than 40% of rated
control supply voltage
12.0 Miscellaneous For RDOL feeders the power contactors shall be
mechanically interlocked.

03. Current transformers:

1.0 Type Bar type primaries and 5A (max) secondary with thermal and
dynamic ratings corresponding to the units with which they
are used.
2.0 Accuracy class - Measuring CT accuracy class 1.0.
- Protective CT accuracy class 10 P 10.

04. Control transformers:

1.0 Type Dry type , cast resin
2.0 Voltage 415V/240V
3.0 Primary taps +2.5 %, +5 %

05. Indicating instruments:

1.0 Basic details - Shall not damage by passage of fault current or existence
of over voltage for the maximum permitted duration of
fault conditions.
- Ammeters for drives above 30 kW shall be CT operated.
- Voltmeters protected by fuses placed as close to the
busbar as possible.
- Maximum reading 600% of IFL for motor feeders .
2.0 Mounting Flush mounting, square dial with zero adjusting device for
external operation .
3.0 Accuracy class 1.5
4.0 Size - Size of voltmeter and ammeter for incomer 144 x 144 mm

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for incoming feeders.
- Size of ammeter for motor feeders 96 x 96 mm.

06. Thermal Overload Relays .

1.0 Standard IEC:292-1
2.0 Basic details - Electronic type (with indication for 37 KW motors and
above)
- Triple pole
- Ambient temperature compensated .
- Inverse time lag.
- Hand reset type.
- Bimetallic with adjustable setting and builtin single phase
protection .
- Reset PB shall be operable from outside .
- Shall be able to withstand prospective short circuit current
without damage or injurious heating till the motor
protection MCCB clears the fault .
- Auto tripping shall be indicated on MCC .
3.0 Contacts 1 NO + 1 NC contacts with minimum rating of
- 10A , 415 V for rated duty AC-11.

07. Magnetic Overload Relays .

1.0 Standard IEC:292-1
2.0 Basic details - Triple pole
- Ambient temperature compensated .
- Adjustable time lag feature or of instantaneous type.
- Provided with a latch and hand reset feature or auto reset
with flag indication .
- Adjustable current setting and time delay calibrated
between nominal current and twice nominal current rating
- 10A , 415 V for rated duty AC-11.

08. Push Buttons

1.0 Standard IEC 60947
2.0 Basic details - All push button switches including illuminated push buttons
shall be of sturdy design
- Un-shrouded actuator for "START" application, Mushroom

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actuator for "EMERGENCY STOP" application and key
"STOP" application for "LOCK-OUT" application shall be
provided.
- Mushroom actuator for Emergency Stop shall be latched
type.
- Press to latch in operated position and turn-to- release in
unactuated position.
- Double break parallel contact design or other suitable
design feature enhancing contact reliability required in
circuits with electronic interfaces involving low voltages
and small currents shall be adopted.
3.0 Size - 22.4 mm diameter
4.0 Contact rating - Minimum 2 NO + 2NC contacts with following current
ratings .
Continuous - 10 A
AC 11 - 1.5 amps at 240V
DC 11 - 0.5 amps at 110 V DC, L / R - 40 ms
- All contact faces of contacts shall be of silver or silver
alloy.
- Facility of adding add on contact blocks to be provided
5.0 Colour Accept - Blue
Test - Yellow
Reset - Black
6.0 Protection class - IP 66/ 67
- The P.B. switches shall be with higher contact reliability,
electronics compatibility .

09. Indicating Lamps

2.0 Type - LED Cluster type
2.0 Basic details - Sufficient number of lamp grips shall be provided for easy
replacement of lamps.
3.0 Size - 22.4 mm diameter
4.0 Voltage level - Suitable for any of the following voltages as per the system
requirement :
415V AC / 240V AC / 110V AC / 24V DC / 220V DC
- All indicating lamps shall be suitable for continuous
operation at 90 to 100 percent of their rated voltage.
5.0 Colour

- For motor ÒN, valve/damper/gate
OPEN, supply ÒN, breaker `CLOSE : Red
- For motor ÒFF, valve/damper/gate
CLOSE, supply ÒFF, breaker ÒPEN : Green
- Fault indication, over load, alarm : Amber
condition, SERVICE & TEST POSITION

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indication.
- General purpose indication, : White
motor ÀUTO TRIP.
Other colours may be adopted depending upon particular
application as approved by the Purchaser.
6.0 Protection class IP 66/ 67
7.0 Layout of indication
lamps on boards /
panels
Indicating lamps shall be located just above the associated
push-button / control switches.
Red lamps shall invariably be located to the right of green
lamps.
In case a white lamp is also provided, it shall be placed
between red and green lamps along the centre line of
control switch/ push button pair.
Blue and Amber should normally be located above the Red
and Green lamps.
When associated with push buttons, red lamps shall be
directly above the green push button and green lamp shall
be directly above the red push button.
8.0 Legend plates Anodised aluminium

10. Miniature Circuit Breakers (MCB)

1.0 Type Heat resistant plastic moulded type
2.0 Ref . Standard IS: 8828 1978
3.0 Protections MCBs shall be provided with
quick break trip-free mechanism
direct acting thermal overload
short circuit trip elements.
4.0 Short circuit capacity Not less than 9000A at 0.8pf
5.0 Mounting DIN Channel mounting .
Single phase MCBs mounted adjacent to each other and
connected to different phases will be provided with
adequate insulated phase barriers.
6.0 Current Rating The MCBs shall be selected from standard current
ratings.(As per SLD)
Motor duty MCBs will be provided, if specified.
MCB shall be of C curve .

11. Selector Switches

2.0 Basic details - All control selector switches shall be of sturdy design .
- Shall have modular construction with number of switching
contacts for each position operated by a single shaft.
- Inscription for each position shall be provided.
- Stay-put or spring return arrangement shall be provided

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as per the circuit and control/operational requirement.
- The contacts shall be designed for higher contact
reliability and electronics compatibility involving low
voltage and small value of currents.
- The operating handle shall be robust and strong.
- One number of potential free switching contact for each
position shall be provided as spare.
- Control switches for circuit breaker ON/OFF control 3
position spring return to neutral with lost motion device
and pistol grip handle.
- Other control and selector switches - stay put type with
wing type knobs.
- All the selector switches shall be of 10 A rating
- 25A for sturdy applications .
- 1 NO & 1 NC contact / poles shall be potential free for
PLC inputs .

1.02.12 LOCAL CONTROL STATIONS

1.0 Material Sheet steel (CRCA)
2 mm thick
2.0 Mounting Wall / structure mounted .
3.0 Enclosure class IP-54 (for indoor installation)
IP-55 with canopy (for outdoor installation)
4.0 Door opening Hinged type front door opening .
5.0 Cable gland Removable undrilled .
To be provided on both top and bottom.
6.0 Internal wiring 2.5 mm , single core , stranded , black PVC insulated copper
conductor .
7.0 No.of components like
ON/OFF PB's , selector
switches etc.
As per scheme requirement.
8.0 Contact details of
components .
All the components like ON/OFF PB's , selector switches etc.
shall have 2NO + 2NC contacts / poles of 10 A rating.
1 NO & 1 NC contact / poles shall be potential free for PLC
inputs .
9.0 Stop push button
details
Stop push button shall be :-
RED in colour.
Mushroom headed.
Press to lock and turn to release type .
10.0 Start push button
details
Start push button shall be
GREEN in colour.

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Shrouded type .
11.0 Lamp details (if any) High density LED type .
12.0 Location of selector
switches
Local / Remote selector switches shall be installed in the LCS
13.0 Terminal blocks - Shall be able to terminate wires of 2.5 sq.mm size .
- Not more than two wires shall be terminated in a single
terminal block .
- Shall be mounted on D-channels .
- 30 % spare terminals shall be provided .
- Colour of TBs for different voltages shall be different.
14.0 Miscellaneous LCS shall act as field junction box also for wiring termination
from Limit switches, PCS, BSS and other field devices.
Facility for termination of minimum 5 nos. 19X2.5 core shall
be provided.
15.0 Provision of ammeter. For motors of more than 45 KW ammeters along with 4
position selector switches shall be provided .
16.0 Earthing Earthing studs shall be provided on two opposite sides .
Internally the earthing studs shall be connected with the body
through green colour PVC insulated copper flexible wire .
17.0 Paint Shade no. 631 of IS : 5 - 1992.

1.02.13 CONTROL DESK

1.0 Material Sheet steel (CRCA)
2.5 mm thick
2.0 Mounting Free standing
Floor mounting pedestal mounting or trunion mounting.
3.0 Enclosure class IP-52 (for indoor installation)
IP-55 (for outdoor installation in bays)
4.0 Door opening Hinged type front door opening .
Hinged top cover with latching facilities in open position
5.0 Cable gland Removable undrilled .
To be provided in bottom.
6.0 Internal wiring 2.5 mm , single core , stranded , black PVC insulated copper
conductor .
7.0 Angle of inclination 8 degrees
8.0 Components like
ON/OFF PBs , selector
switches etc.
Control switches, push buttons and indication devices
mounted on top cover and wired upto terminal blocks
using extra flexible appropriately insulated wires.
Numbers of components shall be as per scheme

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requirement.
Construction and switch layout to provide comfortable
operation .
9.0 Lamp test PB To be provided
10.0 Contact details of
components .
All the components like ON/OFF PB's , selector switches
etc. shall have 2NO + 2NC contacts / poles of 10 A rating.
1 NO & 1 NC contact / poles shall be potential free for
PLC inputs .
11.0 Emergency stop push
button details
Emergency stop push button shall be installed on top right
side of the control desk .
Emergency PB shall be :-
o RED in colour.
o Mushroom headed.
o Press to lock and turn to release type .
12.0 Start push button
details
GREEN in colour.
Shrouded type .
13.0 Lamp details High density LED type .
14.0 Terminal blocks Shall be able to terminate wires of 2.5 sq.mm size .
Not more than two wires shall be terminated in a single
terminal block .
Shall be mounted on D-channels .
30 % spare terminals shall be provided .
Colour of TBs for different voltages shall be different.
Uniform color-coding to be followed for cabling, TB, etc.
15.0 Spare switches At least 02 nos. of each types of switches and indication
lamps are to be provided as spare in each desk .
Two numbers of drilled holes are to be provided . The
holes shall be plugged with rubber cap .
16.0 Earthing Earthing studs shall be provided on two opposite sides .
Internally the earthing studs shall be connected with the body
through green colour PVC insulated copper flexible wire .
17.0 Paint Shade no. 631 of IS : 5 1992 or RAL 7032

1.02.14. CONTROL SYSTEM CONCEPT AND PHILPSOPHY

01 The electrical control system shall be laid on distributed hierarchical concept with a
great extent of decentralization of control functions so that individual system shall be
autonomous in operation as far as possible.

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The system shall be sufficient to perform all the functions required of them & shall be
designed to achieve high degree of accuracy of control functions.
Two hierarchical levels has been envisaged as indicated below :-
Individual drive control level (Level-0)
Functional group control level (Level-1)

02 Individual drive control level (Level-0)

This shall comprise of motors, field devices, HT/LT Switchgears, Intelligent MCC's,
Local control stations, speed control equipment etc. which are to be connected to
Level-1 System.

03 Functional group control level (Level-1)

It shall comprise of Programmable Logic Controllers (PLC). The PLCs shall be
provided for control, interlocking and sequencing of different drives. This shall also
include HMI, visualization, alarms logging, reporting, trend curves, controlling of set
points, etc. for the plant units.
Necessary interface to Level-2/3 System shall be provided.

04. Drive Control Requirement

All process drives shall be generally be controlled from Central control room through
Operator workstations / VDU's and keyboards. Use of Control desks / Control Cabinets
shall be restricted to specific drives / emergency operation only.

All drives shall be provided with sel.switch for local operation / maintenance. LCBs shall
be provided with start & stop PBs, Local / Remote Selector switch, any other devices /
lamps for the operation of the equipment. Stop PB shall be lockable type with key to
release.

For HT motors, ammeter shall be provided on LCB. Interposing CT of secondary 1A
shall be provided with purchaser's switchgear at the middle phase for remote metering.

All pumps shall be provided with dry running protections.

For all motors, drive status (ON/OFF, open/close, forward/reverse) tripping due to O/L,
earth fault, equipment fault, process faults etc. shall be displayed in VDUs.

Where speed control of process drives are envisaged, the speed indicator shall be
provided in VDU.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lUU o 2U5
1.02.15. Automation System :-
01. General
A. Automation System Architecture
1.0 System
Architecture
- Client server architecture

2.0 Redundancy - Dual redundant CPU with hot standby mode (Application
software based redundancy is not acceptable).
- Dual redundant communication bus with dual
communication cards / dual redundant interface module
for the communication bus and each I/O chassis to be
installed in each I/O rack / scanner units and
synchronizing modules .
- Two numbers of servers shall be provided with hot
redundant mode .
- Power supply redundancy .
- Respective I/O rack shall act as a node to the I/O bus for
interfacing with processor rack and shall not be interfaced
through back plane extension between two or more I/O
racks.
3.0 Speed of commn.
interface at I/O
level
Preferably 5 MBPS or better .
Data loss shall not be more than 4 % .
4.0 Connecting ports - Cat.-5, UTP cable with provision for 2 nos. additional UTP
ports .
- Two ports for connection to Level-2 network shall be
considered for the network.
5.0 Level-2 network
communication bus
In place of industrial ethernet, any other deterministic
network of 10 MBPS or better (Bus based on open protocols
at minimum 4 OSI layers) may also be considered in which
case, separate gateway interface with two UTP ports with
TCP/IP protocol on Ethernet shall be provided for Level-2
network.

B. General
1.0 Control Philosophy

- All process data acquisition & monitoring functions,
process control (PID), interlocking, logic & sequence
controls of drive and various systems shall be performed
by the PLC.
- PLCs shall be connected to two different bus levels in the
network . It shall communicate with RIOs , intelligent
MCCs , VFDs , Soft starters, weigh panels etc. on
Profibus / Modbus / Controlnet while with HMIs and HMI
cum ES on high speed Ethernet bus through server . The
Ethernet switch provided shall be manageable type .
- The automation system shall cover all the sections of the
entire plant .
- A separate server shall be provided for MIS terminals to
be located in welfare building of the individual shop
through communication link switch .
- Communication gateway shall be provided for
communicating the system with plant network system of
the plant .
- For displaying the alarms and faults in the mobile handset

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lUl o 2U5
of the authorized person a modem for GSM shall be
provided in the network .
- PLC installed in mobile equipments like stacker cum
reclaimer etc. shall communicate with the main server
through wireless communication . All the required
hardware and software shall be provided for the same .
2.0 Data signals
exchangeability
with PLC
- The PLC envisaged in this package shall exchange
signals with RIO / Instrument panel / VFD / MCC's /
Weigh Feeder Panels / dedicated position control system
panels (if any) / Level 2 system computers / other PLCs of
the plant.
- However all the critical equipment / drives shall be
provided with hardwire interlocking in addition to the
interlocks through PLC .
- The Tenderer shall include multi-vendor connectivity with
all requisite hardware , communication interfaces &
required software for exchange of signals with other PLCs
of different make on high speed communication bus.
- OPC server shall be provided for communication between
the OEM PLC (of different make) and main system PLC .
3.0 Operational control
mechanism
- Provision of the visualisation of the system shall be
through human-machine interface HMI , for the control
and operation of the complete plant .
- In addition to the normal workstations, at least two
numbers of 42 or higher plasma/LCD display units and
one overhead LCD projection system to be provided in
each central control room.
- Plasma/LCD display units along with AV switching unit to
output AV signal from any machine in the control room
4.0 Operational
facilities in HMI
The Graphic interface to the operator shall have the following
minimum features with user friendly navigation keys .
It shall be possible to display dynamic graphic of different
section of plant on the TFT screen & large display system
.
Graphic displays shall be field configurable only through
engineering key-board with standard / user defined
graphic symbols.
Different plant sections dynamics shall be displayed on
different pages.
The graphic display on the HMI clients shall also include
extensive process, system and equipment diagnostics in
graphical form for troubleshooting. The PID and other
such settings to be available on operator workstation for
viewing and editing.
Graphic display shall be interactive type through which it
shall be possible to control process. Following process
control functions will be initiated via the HMI :-
- Operation mode (Auto / Remote / Manual ) selection
- Control mode (Auto / Semi-Auto / Local ) selection .
- Selection of drive and control loops
- Set point selection.
- It shall also be possible to send motor start / stop
and shutdown, valve open / close command , control
mode selection command from this display.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lU2 o 2U5
- It shall be possible to go from any graphic page to
related graphic page or any group view or alarm
summary in single keystroke using soft key function.
- Process diagnostic system to provide status & fault
signals of the process along with process error
displays.
- The details of graphic screens shall be finalised as
required during detailed engineering and
commissioning.

5.0 Operational menus
in HMI
Opening page with project description, name of supplier,
name of consultant .
Sub-menus like command menu, report menu etc.
Command menu in the form of buttons for start and stop
of each equipment / group of equipment .
Operation mode
Display of auto / local selection of each mechanism .
6.0 Reporting and data
logging
Summary of faults with description, date and time of
occurrence .
Shift wise, daily, monthly, yearly hierarchical logging of
report/faults/data with process values / production figures
and other process data. However, same shall be finalised
by the Purchaser during detailed engineering process.
Automatic log sheet operation & maintenance shift &
day.
The system shall comprise of a standard library of control,
logic and computational functions that are
preprogrammed and stored in memory. During the
system configuration, user shall be able to select the
appropriate functional blocks from the library, link them
together, set the various inputs and tune parameters
associated with each block.
Real time recording of data for important equipment shall
be provided (e.g high speed recorders etc.)
All logging in ORDBMS. Logging and reporting also to be
provided batch-wise, campaign-wise, etc. Reporting to
include analysis tools.
Historical data storage & trending.
Along with graphic generation, trending, and alarm
generation, EVENT LOGGING also to be included. Event
logging means data related to an event happening in the
process or field. It will also include the user activities vis-
-vis operation through the automation system.
7.0 Mode of operation
of the plant
A Local Mode :-
Operation of single drive / equipment
Start / Stop from LCS shall be done only for test and
repair purposes .
To enable the testing of individual equipment all the
interlocks which are not at all necessary shall be
withdrawn in this mode .
However all personnel / equipment safety interlock
are effective for safety reasons also in local mode .
LCS are provided for all motors , drives and

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actuators for valve operation as near as possible .

B. Semi Auto :-
Under this mode it shall be possible to monitor &
control the plant based on set points / commands
given by operator through keyboard (for individual
equipments or individual group for group control
drives) and the control, sequential operation of
various mechanisms in the required sequence shall
be executed by PLC i.e.; in this case all the changes
are operator initiated.

C. Auto Mode :-
This is the normal mode of operation of the plant . In
this mode , the desired values (set point) of the
parameters of process control loop will be set via
keyboard of the HMI and sequencing and logic
functions will remain operative through the PLC as
per programme.
There shall be a provision of group start of the
individual sections .
In the individual sections there shall be provision of
interlocks , logic and sequencing between the
individual drives

8.0 Screen menu
display
Over view
Group display
Loop display
Mimic display ( dynamic )
Alarm over view
Alarm display
Trend display (Dynamic display)
Event displays(Dynamic display)
Diagnostic & maintenance displays

However a dynamic mimic status pages shall be made
available with security through web based portal for each
respective packages . Location of the same shall be decided
during detailed engineering (by BSP) .
9.0 Process graphic
displays with
dynamic process
variables
Process status overview (On/Off status of process and
plant)
Operation status of Drives (Position and status of drives)
Group display of Loops
Control Loop display & Configuration of Control Loops
Real time trending (Bar graph displays and / or
numerical display)
Historical trending. Historical trending for 7 days for 1
minute scan rate for all analog inputs
Fault message indications
Operational/ event message indication.
Data and time synchronization on the complete HMI
system shall be ensured .

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High speed (1msec scan) recorder of 12 channels to be
provided for real time recording of data for important
equipment (at least 02 nos. for each packages) .

10.0 Process graphic
display operation
Graphic Display will contain static and dynamic
components. The dynamic components display the
actual state of the plant section. Dynamic components
will be actual binary states (e.g. drive on) or actual
values . Values will be represented as bar charts and /
or numerical.
Critical plant status will be highlighted by different
colours or by blinking. Description in clear text will be
provided to simplify Operator understanding.
Double clicking on any of the control valve in any of the
menu / submenu pages shall invoke the corresponding
PID loop display screen with real time trend. PID loop
display screen shall show controller facia and displaying
status and parameters of each controller. Each facia
shall be able to display process value, set value and the
manipulated variable. The remote manual functions and
change of set points under auto mode shall be possible
to be performed from these facias.
Graphics should also include very comprehensive
diagnostics on process, plant, equipment, system etc.,
enabling the user to pinpoint exact reason of any
problem faced.
In case of Cascade/ Ratio control, it shall show all the
controllers facia with the facility of maximising one of
them. PID parameters can be changed only after
validation of software password.
Clicking on any mechanism like valve will invoke a
small screen showing following (software lamps)
indications for remote manual operation :
o Local
o Remote
o Auto
o Open (Blinking with opening color during opening )
o Closed (Blinking with closing color during closing )
o O/L Tripped
o Torque switch actuated
o Control supply Healthy
o Valve Open Timer Time Out
o Valve Close Timer Time Out
o Local Stop
Clicking on any mechanism like fan / pumps will invoke a
small screen showing following (software LED)
indications for remote manual operation:
o Local
o Remote
o Auto
o Run Feed-back
o Elect. Fault
11.0 Colour Codes

The display of the process will occur on full graphic color

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process terminals.
In Graphic display sheets color of the process line shall
be as per the color code followed by the Purchaser.
However all fans / pumps color will be RED in ON
condition, color will be GREEN in OFF condition and
valves will be PINK (with blinking) in the intermediate
position.
Client approved standard color-coding to be followed for
graphics.
Uniform color-coding to be followed for cabling, TB, etc.
12.0 Trending In any menu/ sub menu page double clicking on any tag
will invoke the trend menu of that particular tag. Based
on the selection by the Operator either Historical or Real
Time Trend menu will be displayed. Provision shall be
there so that Operator can add trends by entering the tag
nos. , for another 7 nos. of tags in the same page ,using
the same time base for comparison purpose.

The Automation system must support historical process
information recording and retrieval. This historical
information shall be available for use in logs, trends, etc,
requested at any operator console. Recorded process
information shall include:
Measured value
Alarm status
Setpoint or desired value
Output value
Control mode
A distributed approach to historical recording is preferred
to a dedicated unit. For both logging and historical
trending the operator/ engineer must be able to specify
the points to be recorded, the frequency with which the
data is to be collected and the time base. Historical data
should support the following protocols:
OPC (Open Process Control)
OLE (Object Linking and Embedding)
OBDC (Open data base connectivity)
API (Application Programming Interface)
Sufficient online storage shall be included to
accommodate the data base and alarm, event and
historic data logs for monitoring 75% of analogue data
for 24 hours at 10 sec. Trend rate.
Display of trend shall have
Operator scalable X-axis from 60 seconds to 24
hours (for 24 hours history, trend shall be stored
as 10 seconds scan for each variable)

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Operator scalable X-axis from 8 hours to one
month (for one month history, trend shall be
stored as 10 minutes average value for each
variable).
XY Plots also to be included. Storage frequency,
maintenance, sizing, etc. to be done in
consultation with client.
Current of all motors to be available on L-1
automation system for monitoring /trending etc for
all process related drives.
13.0 Interlocking The interlock scheme shall be as per the technological
requirement based on process flow diagram , P&I diagram
and functional chart .
All emergency conditions like stop push button,
emergency stop command, torque switches , level
switches etc. shall be interlocked to the main power
contactors of the drives.
Provision of providing interlocking of different equipment
(which are controlled from different PLC) based on I/O
exchange from that PLC .
Further the system shall be provided with pre-starting
audio-visual alarm at equipment platform before starting
of mobile equipments like conveyors , turret , tundish
cars etc
Interfacing with subsystems : All outside auxiliaries and
supporting units for process related system shall be
interfaced.
However, all facilities to be provided in the central control
room which shall be finalised during detailed engineering
stage keeping in view the process / technological
requirement.

14.0 Alarms and alarm
management
The use of multi-media system in HMI shall be
envisaged for audio-visual signaling for faults & alarms.
There shall be dedicated key as a provision for
acknowledging the faults. The usability of the operator
interface shall be further enhanced with features such as
sound cards, touch screen, track balls etc.
Alarm list / event list and operator action list and its
logging for minimum one month .
Alarm Performance
Irrespective of Operator activity and choice of display, an
alarm situation shall always have priority and shall be
brought to the attention of the Operator, quickly and
automatically.
The display containing the alarm shall be selected by a
single keystroke action. Alarms should automatically

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lU? o 2U5
update in the event of an alarm operating i.e. it should
not require operator intervention to update alarms either
on process mimics or alarm summary format.
Alarm messages shall be time tagged to within 100
milliseconds (from detection at input card or receipt from
data link) or less and are required to be displayed within
two seconds of the field device operating. System
resolution for the orderly detection of successive alarms
shall enable those alarms to be displayed in order of
occurrence, and/or priority.
In order to facilitate easy recognition of alarm status by
operators, annunciator colours and audio tones shall be
easily distinguishable. All alarms and trips shall be
annunciated by a screen message and an audible alarm.
Critical process alarms shall come in the form of small
size popup window on the HMI screen . Individual area
wise alarm shall display in the corresponding HMI
station.
The alarms and trips shall flash in a highlighted form
(e.g. reverse video) until acknowledged. When
acknowledged from any HMI, the flashing and audible
tone shall stop on all HMIs. When an alarm returns to
normal, flashing shall return to normal on all HMIs
provided the alarm has been acknowledged.
Alarm Category Colours
The following colours shall be used for the process
control system screen alarms, on a black of gray
background:
Fire & Gas : Red
ESD : Magenta
Fault alarm : White
Process alarm : Orange
These are proprietary colours and shall be confirmed
during detailed engineering. The use of yellow colour
(traditionally a gas alarm) and green colour (associated
with normal conditions) shall be avoided for alarms.
Audible Alarm Category
There shall be audible differentiation between the fire
and gas alarms (noise X), and process alarms and faults
(noise Y and Z), where X, Y and Z noises have to be
defined.
Analogue Alarms
All process variables and composed points shall have
the possibility of being assigned at least two levels of
high and two levels of low alarm values. All control loops
shall have the possibility of being assigned high and low

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deviation alarm values. All alarms shall have a user-
definable dead band. An alarm shall be provided when
analogue signals are less than 3.8 mA or greater than
20.2 mA. Rate of change alarms and set point deviation
alarms shall be provided.
Filtering based on plant, equipment, time-span etc. shall
be possible
The system will be engineered such that it is anticipated
that at least 4 levels of alarm priority will be used:
o Low
o Medium
o High
o Critical
According to guidelines, which will be developed in detail
engineering, the Alarm/ event logging facilities will be
provided using Automation System based logging rather
than printers.
Discrete Alarms
o All discrete inputs shall have the possibility of being
assigned a change of state alarm. Discrepancy
alarm indicating failure of control action shall be
provided.
Alarm Analysis
o It shall be possible to inhibit alarms by point of priority
when the initiating device is faulty or being
maintained. While inhibited, the point must still be
scanned and archived. The removal of the inhibit
shall be logged. A summary display containing all
inhibited points shall be provided on demand. Alarm
inhibition shall be permitted from any of the work
stations with level 3 or 4 access level only. Facilities
shall be provided to mask out alarms from equipment
(such as pumps) that is shutdown. These alarms
shall be automatically or manually via keyboard,
reinstated when the equipment is put back into
service. Initiation and removal of inhibition shall be
logged as an event and printed.
Alarm Display
o Alarm displays shall take the form of a summary
display of all points in alarm, and/or integrate the
alarm message with associated item, group or
overview data. Alarms shall be listed in order of
occurrence, and for specific alarm displays the most
recent alarm shall be shown at the top of the display.
All alarms shall be identified by tag, description and
the date and time of the occurrence, in hours,
minutes and seconds. A banner type display

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showing a summary of alarms shall always be
present at the top of the screen irrespective of main
display.
Alarm Grouping and Priority
o Alarms from an area shall be capable of being
grouped in one or more Alarm Groups. A minimum
of 30 Alarm Groups shall be provided. At least four
levels of alarm priority shall be available, with
configurable presentation/ background colour. A
global alarm acknowledge and reset facility shall be
available. If unacknowledged, Alarm message stays
on display until it is cleared.
Diagnostic Alarms
o The Automation System shall have a comprehensive
self-diagnostic alarm information shall identify the
faulty device down to board level, with its location
and provide a diagnostic code. Individual circuit
boards shall be provided with LED indicators or
equivalent, to positively identify a faulty board. The
failure of any single item of equipment shall not
generate erroneous alarms.
Alarm Handling Capacity
o In addition to the alarms included in the point count,
the Automation System shall be capable of handling
alarms and status points received via any data link
to which it is connected.
Alarm Flooding
o The Tenderer shall outline his approach, to over
come the problem of alarm flooding.
15.0 Configuration For Instrumentation system a separate dedicated PLC
shall be provided (as mentioned in TS) .
If the PLC is common for the process a separate
dedicated remote I/O panel shall be provided for the
instrumentation system .

02. Programmable Logic Controller (PLC)

General Features

1.00 Power supply system
1.01 Power supply
system

PLC system shall have two independent Input supply voltage
:-
- Two source of 240V AC single phase, 50 Hz from UPS for
CPU and other required control modules , interrogation
voltage and output voltage .
- Two nos. of redundant power supply modules in each
chassis with diode ORing .
- One source of 240 V AC single phase, 50 Hz from MCC for

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auxiliary power supply e.g fans , panel lamps , power
sockets etc.
- Both UPS power supply units shall have auto changeover
facility as well as manual changeover facility through
selector switch .
- Redundant 24 V DC regulated power supply unit shall be
provided for interrogation voltage and output voltage .
- Separate power supply bus shall be provided for
interrogation voltage supply for all inputs and output
respectively (even if the input interrogation voltage and
output voltage is same)
- Power supply unit shall be provided with diode multipliers
for input interrogation & output voltage for driving outputs
(interposing relays, solenoid valves ,lamps etc.).
- DP MCBs shall be provided for each rack of the PLC
system .
- 20 % spare DP MCB shall be provided in each panel .

1.02 Built-in power
supply units
- Suitable for the power supply system as specified above.
- Following power supply unit shall be provided for following
units :
Redundant 24 V DC power supply units (with multiplying
diodes for powering field instruments (2-wire
transmitters).
Separate power supply modules, to be supplied by the
Tenderer for each segment of Foundation Field bus
system, shall be of Type 132: Non-I.S. power supply
intended for feeding a non-I.S. barrier. Output voltage
shall be 32 V DC maximum. Power supply module shall
have in-built power conditioner. DP MCBs shall be
provided for each segment of the Foundation Field bus
system.
- Redundant regulated power supply unit of proper rating
shall be provided for special control module ( if any
required).

Following features shall be provided in the power supply unit
mentioned above .
- Insulation level 2.5 KV for 1 minute.
- Protection against surge protection & short circuit
- Electronic over current protection with feedback feature.
- Thermostat protection against over temperature .
- Over voltage protection .
- Fuse protection in the input and output circuit.

2.0 Central processor
unit
- Modular and plug-in type
- 32 bit microprocessor based
- PLC shall be able to scan and execute all close loops
(approx. 40 PID loops) in less than 100 milliseconds and
scan digital inputs in 50 milliseconds simultaneously.
- Execution time between 1 milliseconds to 3 milliseconds
per 1K instruction or better.
- Provision to latch desired outputs.
- Provided with redundant hot standby CPU (with

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appropriate communication module).
- The CPU system shall have facility of bumpless transfer
in case of failure of one .
- CPU shall have crystal clock generator .
- Redundant CPUs to have extensive in-scan
synchronization. Time synchronization from designated
time server
- Peer to peer communication through I/O channels shall
be possible .
- Backup system communication (redundant
communication bus) shall be provided.
- The processor shall have proper communication
modules (for each CPU) for communicating with
redundant processor , remote I/O modules and for
communicating with other communication bus protocols
like ethernet bus / profibus / modbus / controlnet / field
foundation bus etc. (no proprietary bus, for any sort of
communication including fieldbus, to be used.
- The processor shall have in-built provision for software
timers , counters , examining input conditions, compare,
compute, logical, conversion from/ to BCD, bit
manipulation, block memory manipulation, diagnostic,
shift, sequencing, conditional jumping, subroutine
instructions etc.
- CPU shall be capable of handling PID functions including
mathematical functions ,weighing and batching functions.
- CPU shall be capable of handling 30 % additional (future)
I/Os over and above 20 % spares (installed) I/Os
indicated in basic configuration diagram. Maximum CPU
loading shall be limited to 60 % for the intended
applications.
- The CPU shall have the facility of initializing a
synchronizing pulse to the server periodically (Minimum
once in a day).
- CPU loading shall not exceed 60% .
3.0 Timers

The timers shall be OFF delay, ON delay ,retentive type timer
with a range from few millisecond to few hours .Accuracy
shall be +/- 0.1% of the set value .
4.0 Counters The counters shall be of counter up and counter down type .
It shall have the range from 0000-9999 .
5.0 Memory units - Modular and plug-in type
- Word length 32 bit
- Expandable in blocks of 4K Words
- Minimum size 20MB .
- EPROM/ RAM with battery power back-up
- Back-up battery shall be as follows :-
Rechargeable Ni-Cd batteries with necessary charging
circuit / Lithium or any other internationally acceptable
type.
Able to retain memory for a minimum of 1 year with no
power applied to the controller.
6.0 Input Units - High density, modular, rack based (channel based I/O
not acceptable) and plug-in type.
- Insulation level of 1.5 KV

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- Input interrogation voltage 24 V DC.
- Individual fuse for each unit shall be provided for
protection against cable fault/earth fault .
- For critical applications all inputs (analog, digital, others)
to have individually isolated channels.
6.1 Digital Input
Modules
Digital input units shall have the following features :-
16 / 32 inputs per module.
Time delay of about 10 millisecond to filter out noise
and contact bounce .
Optocoupler to galvanically isolate each input device
from the decision making logic of the controller
LED status indication
BCD input units suitable for four digit input
Pulse inputs ( Incremental encoder / digital tacho )
Absolute / incremental encoder inputs.
High speed counter type inputs
All the cards shall be compatible of receiving digital
signals from field sensors and switches directly .
All the control modules / cards shall be lacqured .

6.2 Analog input
Modules
Analog input units shall have the following features:
Shall be 8 channels, rack based & plugin type..
Suitable for 4-20 mA / 0-10V DC / RTD /
thermocouple / weighing signal inputs.
With necessary A/D converter having at least 12 /
14 bit resolution based on application.
Suitable for J/K/S type thermocouples & for PT100,
2- wire / 3 wire
Galvanically isolated differential inputs with insulation
level of 1.5 kV.
For 4 20 mA analog inputs, fused TB with blowing
fuse shall be provided.
Healthiness of every input shall be monitored & LED
indication shall be provided.
Analog module shall have the facility to be
configured in voltage or current mode and differential
or single ended inputs mode .
Pulse/ frequency input module shall have range upto
50 kHz. For very high frequency applications, the
range shall be upto 1 MHz.
All the cards shall be compatible of receiving analog
signals from field sensors and switches directly . If
not suitable converters shall be provided .

7.0 Output units - High density, modular, rack based (channel based I/O
not acceptable) and plug-in type.
- Insulation level of 1.5 KV
- Individual fuse for each unit shall be provided for
protection against cable fault/earth fault.
- For critical applications all outputs (analog, digital, others)
to have individually isolated channels.

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7.1 Digital Output
modules
Digital output units shall have the following features:
16 / 32 digital outputs per module .
High Density modular and plug-in type .
Isolated outputs with two separate terminals for each
outputs .
Rated for 24 V DC
With insulation level of 1.5 KV
The output module shall be able to drive interposing
relays (24V DC coil), solenoids, annunciation lamps,
LEDs, Instrumentation control equipments etc.
Power devices like contactors etc. shall be actuated
through interposing relays. The interposing relays
shall be mounted in the same panel. Proper surge
suppressor shall be mounted across the coil of the
output relays. However as far as possible interposing
relays to be avoided.
Any special requirement e.g position control to
control field devices shall be met by using separate
interface modules.

- BCD output units shall be as follows: -
Suitable for four-digit output.
Rated to drive seven segment LED displays

7.2 Analog output
modules
Analog outputs shall have the following features:
Shall be of 4 / 8 analog output channels .
Suitable for 4-20 mA / 0-10V DC / +/-10V DC outputs
With necessary D/A converters having 12 bit
resolution
Each output shall be galvanically isolated.
8.0 Foundation Field
Bus Interface
modules (FIM)
The Foundation Field bus interface modules (FIM) of the
PLCs shall be chasis based modules. These modules
shall completely integrate Foundation Field bus devices
with the PLC controller & HMI software. These FIM
modules shall deliver system wide integration of data
access, control, connections, diagnostics and alarms
with the PLC system. LED indication of power, error
condition & status shall be provided in each FIM module.
PLC shall provide graphical support to the Field Bus
Interface module to perform the functions of Link Active
bus scheduler for a network. This will allow the system
configuration engineer to see whats going on and shall
provide complete flexibility to adjust schedules based
upon the needs of the control scheme. PLC shall also
support Back-up Link active scheduler.
All Foundation Field bus (FF) devices (to be procured
under separate Instrumentation package) shall be

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registered with the Field bus Foundation at level ITK 4.0
or higher. Field bus interface modules & Field Bus
Library manager shall be compatible with ITK 4.0 or
higher version compliant devices. Tenderer shall also
provide Field bus usage license. All FF devices provided
shall be polarity insensitive. All FF cables shall be of
Type A.
The PLC offered shall be certified for the Foundation
Field bus Host Inter operability Support Testing (HIST)
from Foundation Field bus organisation. HIST
procedures provide a common methodology for
assessing host inter-operability with registered devices.
PLC Software shall have the capability either to directly
read Device description (DD), files from the Field bus
devices and add these DDs/ Files to the library for Off-
line & On-line configuration, or it shall perform this task
through a separate software tool, Field bus library
manager. It shall be possible for PLC based automation
system to upload field device configuration changes
implemented in the field. Once the configuration
information is stored in the automation system, it shall be
possible to download it to any other similar device,
whether a new or replacement device.
In case of a new device added to a Foundation Field bus
segment, its presence shall be immediately shown in that
segment. Important information about the new device
including tag name, address, model and revision shall be
immediately available.
Downloading new software to Foundation Field bus
devices shall be possible from the PLC. There shall be
no need to physically change the firmware and to
disconnect or remove devices for updating to the latest
available revision. It shall be possible to simultaneously
download the latest firmware to multiple field devices.
Each Foundation Field Bus interface module shall
support minimum two segments.
The Terminators shall be impedance matching modules
to be used at or near each end of a segment. There shall
be two terminators per segment. The terminators
prevent distortion and signal loss and shall be supplied
as a pre- assembled, sealed module. Tenderer shall
provide the Terminators as per the requirement.
The power for each Foundation Field bus segment shall
be provided through a power conditioner to prevent the
communication signal from being attenuated by the
power supply & to eliminate cross talk between FF
segments through a common power supply.
Power supply modules to be supplied by the Tenderer
shall be of Type 132: Non-I.S. power supply intended for
feeding a non-I.S. barrier. Output voltage shall be 32 V
DC maximum.
For Field bus use, a power supply impedance matching
network shall be provided. This shall be a resistive/
inductive network and built into the Field bus power

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supply module.
Connectors as coupling devices shall be employed to
connect the wire medium to a field bus device or to
another section of wire. Standard field bus connectors
shall be used. Specification shall be as per annexure A
of the ISA physical layer standard and annexure A of the
IEC physical layer standard.
Couplers shall be the physical interface between
segment and spur or segment and Field bus device.
Field bus couplers shall be as specified in the IEC/ ISA
physical layer standard and provide one or several points
of connection to a field bus segment.
Grounding: The instrument signal conductors shall not
be used as a ground. Instrument safety ground shall be
made through a separate conductor outside of the signal
cable. The conductor may be in the same cable as the
instrument signal conductors and shield, but shall be
located outside the shield within this cable. Field bus
devices shall not connect either conductor of the twisted
pair to ground at any point in the network. The Field bus
signals are applied & preserved differentially throughout
the network. Network cable shield shall be earthed/
grounded in one location only, at the field termination
assembly (Host) end. At any field instrument, cable
shield shall not be connected to the instrument earth/
ground or chassis. The cable shields from different
networks shall not be attached together in a field junction
box. This will create ground loop & noise onto the
network.
Lightning/ Surge protection: Surge protection shall be
provided for all field devices. The surge protection shall
consist of low capacitance silicon avalanche diodes or
spark gaps, wired for both normal & common mode
protection and connected to the electrical safety ground
grid. Surge suppressors shall be so selected that they
shall not measurably attenuate the FF signal. To avoid
any chance of short circuit, surge suppression devices
shall be connected through a series fuse.

Foundation Field bus Network/ segment naming convention

The following recommended network/ segment naming
convention shall be followed:

# NN MM P
#: Indicates the plant/area number to which the segment
shall be connected.
NN: Indicates the node number / controller name.
MM: Indicates model number/ card number.
P: Indicates segment or port number.

Loop & Instrument Naming convention :-
Loop & Instrument naming convention shall be decided
during detail engineering.

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Spur Naming convention :-
All spurs shall be labeled with Instrument tag name.

9.0 Additional features
- On-line replacement of any module shall be possible in
such a way that the removal and addition of any module
shall be possible without de-energizing the system.
Further there shall not be any interruption in the system
while replacing a faulty module except for the inputs /
outputs which are being handled by the module.
- Fully pre-programmed connection of field devices with
input units through ordinary multi-core copper control
cables of 1.5 sq. mm size (twisted pair) , upto a length of
500 m.
- Communication with computer in distributed hierarchical
control system and operator consoles / display units.
- High speed communication among PLC and operator
consoles/ display units shall be provided through dual
redundant TCP/IP Ethernet using ethernet cards (no
propriety cards) on HMI station .
- Switch to disable all outputs of the controller during start-
up / debugging .
- All the automation equipment shall be user configurable to
a fail-safe state to avoid dangerous situations in case of
any failures caused by power failure, communication
failure, etc.
- Test sockets on input modules for input simulation
- Facility to be provided to hook up engineering station at
each location of I/O (preferably) .
- Serial interface, RS232C and better shall be provided
- Any special requirement to control field devices shall be
met by using separate interface modules.
- The PLC system shall be immune to the following: -
Radio frequency interference
Electromagnetic interference (EMC compatible)
Power system spikes
The methods and standards followed for these features shall
be furnished .
- All network cabling to be structured and to be tested and
certified.
- Network teams from multiple switches to be employed for
all the important machines (computers).
10.0 Mounted spares - Min of 20 % of I/O modules used (with at least one module
of each type) for input and output shall be offered as
spare for each programmable controller and the same
shall be mounted and wired to the terminal block in the
cubicle suitably.
- No. of spare Channel per card shall be 20 %.
- 20 % spare memory capacity shall be provided
- Provision shall be provided with empty slots for future
expansion for 20% I/O modules. Minimum 50 % spare
memory capacity shall be built in the system after loading
of application and system software.

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- 01 number each of DI+DO cards per each PLC shall be
provided as spare .
Spare capacity of the spares mentioned above shall be
applicable at the time of handing over of the plant .
11.0 Self diagnostic
features
- Parity errors, cycle errors and under voltage
- Failure in central processor unit, memory and power
supply.
- Indication of type of failure
- Automatic turning OFF of all outputs or optionally holding
of all outputs in their last state on failure detection.
- Fault detection upto card level .
- Communication failures all types
- Fuse failure indication for outputs

12.0 Monitoring
functions
- Monitoring of internal voltages
- CPU Status monitoring
- Memory status monitoring
- I/O Status monitoring
- Address monitoring
- Bus & communication signal monitoring
- Broken sensor detection
- A milliammeter with selector switch shall be provided on
panel front to monitor the earth leakage current.
13.0 Terminations

- All inputs and output wired up to easily accessible
terminal blocks rated for 660V
- Screened cables for mA signals from Instrumentation I/O
rack and other field sensors to terminal blocks of PLC.
- Control cables for contact signals from Instrumentation
I/O rack to terminal blocks of PLC.
- Suitable for terminating up to 2.5 sq. mm. copper
conductor industrial control cables.
- Fuse terminals for all input & output signals (with LED
indication).
- Required test and maintenance equipment to be provided
for maintenance and troubleshooting of FO and wireless
communication.
- As far as possible cross-ferruling to be used for all
connections.
14.0 Earthing - Separate earthing bus for power / panel earthing and
electronic earthing shall be provided. Minimum two
numbers of electronic earth pits shall be provided for each
set of PLC .
- Electronic earthing bus shall be suitably insulated. Earthing
requirements / earthing schemes for the equipment
supplied shall be clearly indicated in appropriate
drawings.

15.0 Constructional
features
- Unitised construction .
- Floor mounted, free standing and indoor type.
- Bottom cable entry through gland plate.
- Sheet steel clad

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- Dust and vermin proof
- Anti vibration pads to be provided to withstand vibrations
as per application.
- All modules plug-in type.
- Panel illumination with door interlock limit switch.
- Switch-socket outlet for maintenance.
- Suitable fans & inlet air filters shall be provided at the
bottom/ top of each panel for proper air circulation.
- Empty slots of the racks shall be provided with dummy
cards for protection against dust & damage.
- Colour shade outside and inside shall be RAL 7035.
- All panels shall be of Rittal make.

16.0 Enclosure

- Conforming to IP-42 class in PLC room/control room.
- Conforming to IP-54 class for remote I/O cubicles
located in shops/ bays.
- Programmable controllers, even if housed in air-
conditioned enclosure, shall be suitable for normal
industrial environment and ambient temperature upto
50C.
- Temperature while operating
Lower limit : 0 degree C
Upper limit : 60 degree C
- Temperature while not operating (storage)
Lower limit : 20 degree C
Upper limit : 75 degree C
- Relative humidity
Daily average 80 to 90% (8 hrs.) and 65 to 90%
(16 hrs.)
Maximum 98%, not occurring simultaneously with
maximum temperature.

17.0 Data sheet to be
furnished by the
tenderer
Tenderer shall submit the data sheet of the PLC system .
The following informations shall be at least mentioned in the
data sheet :
CPU processing speed
I/O handling capacity
CPU in built communication port
CPU programming memory capacity
Minimum scan time achievable
CPU self and diagnostic features .

03. Human Machine Interface (HMI) Work Station & Engineering Station

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1.0
Type - Shall be console type PC based colour graphic Work
Station
- Commercial grade latest available in the market.
- Industrial grade latest available in the market (for
installations in the plant bay e.g. on casting platform in
MOP)
- In addition to the normal workstations, at least two
numbers of 42 or higher plasma/LCD display units and
one overhead LCD projection system to be provided in
each central control room.
2.0 Interfacing card /
module required
Proper interfacing card / module with related communication
protocol shall be installed in the programming unit so that it
can communicate with the network (i.e PLC processor ,
server , HMI , printers) smoothly

3.0 Programming
Facilities
- Programming unit shall be suitable for developing
programs in ladder diagram / block diagram / statement
form / SFC.
- Programming unit shall have facility for loading the
program from CD & DVD .
- The programming terminal shall be capable of developing
multiple programs offline without connecting to the
programmable controller. Upload and download of the
program between PLC and program unit shall not require
compile before download .
- Engineering station shall have an integrated and
development and configuration setup for all the drives ,
instruments , PLC/DCS , HMI etc.

4.0 System
Configuration
- Industrial grade PC with Pentium CPU
- 19 TFT color monitor with 0.28 mm dot pitch 1280 * 1024
resolution
- Dual Ethernet interface with LAN accessories for all PC
based operator station
- 64 bit , 256 MB RAM, 80 GB Hard Disc drive & controller
- Combo Drive, Graphics Accelerator Card with minimum 8
MB on board RAM, Keyboards, Track ball / Mouse, Tape /
Data backup drive suitable for plugging in USB port.
- The computers shall be provided with minimum 3 serial
ports & one parallel port, ethernet interface with
accessories.

5.0 Functions - Error detection and reporting.
- Fail safe / broken sensor information and alarm and their
reset .
- Selection of highest / lowest signal from a group of
accepted inputs and displaying the same
- Linearisation and other arithmetic calculation. Provision
shall be kept for pressure and temperature correction to be
computed for flow measuring loops.
- Built-in ambient temperature compensation for
thermocouple inputs from field.
- Trending real time and historical (Trending shall be

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provided for all analog inputs).
- Report generation and periodic logging.
- Developing of graphic symbol library as per
ISA 5.1 and 5.3. in addition to standard industrial
symbols.
- Printing of alarm conditions with parameter identification.
- Online editing of :-
Scan sequence
Identification number
Engineering units
High and low alarm limits
Alarm dead bands
Addition / Deletion signals
Removal / introduction of analog and digital points in
scanning.

6.0 Miscellaneous - Networking via Ethernet with Network diagnostic
displays
- Ability to add optional packages (e.g. for data analysis)
- All the important drives should be provided with suitable
CBM systems such as vibration monitoring, current
signature, temperature etc. Information from CBM
systems to be interfaced to HMI system as well as plant-
wide CBM system.
- All equipment to have extensive diagnostic capability.
This information to be used for generation of relevant
diagnostic information on working and problems in the
system.
- Extensive BOM covering all hardware, software, etc.
should be provided.

7.0 Printer Latest appropriate model of HP Laser Printer to get hard
copy of the program dump / data logging / alarm logging /
event logging / data trending etc.

04. Server :-

1.0 System
Configuration
- Industrial grade .
- Server grade Intel Xeon, Dual CPU (Resultant speed 3.06
GHz)
- 4 MB Cache memory.
- 512 MB RAM.
- 2 X 72 Hot swap SCSI HDD (RAIR level-1 Disc mirroring) .
- 1X1.44 MB FDD.
- Combo drive
- 2 Serial ports, 1 parallel port, 2 USB port (for all client as
well server).
- Graphic accelerator card with minimum 8 MB onboard
RAM)
- Dual Network interface.
- 19 TFT colour monitor
- Keyboard and Mouse.
- Operating system Windows 2000/NT.

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2.0 Make - Servers shall be of COMPAQ/ DELL/ IBM make.

3.0 HMI server - HMI serves shall be redundant. Separate clustered/
redundant servers to be considered for data servicing.
The server to be of latest & proven specification at the
time of implementation.
4.0 - Only client-server, multi-tier system to be used. No
standalone workstations apart from emergency
workstations. Number of operator stations and
emergency workstations to be finalized during
engineering stage and should have at least two and
one hot spare respectively

05. Software :-

1.0 PLC System software
(Windows
Programming)
The PLC programming software shall be latest, Windows
based, menu driven and shall support the following minimum : -
- Cyclic, Time Controlled, Interrupt controls.
- Retentive / Non Retentive Timers, Bi- Directional counters,
latches, etc.,
- Internal Flag generated by the PLC.
- All Boolean Logic Functions
- Data Transfer, Block Transfer
- Sub Routines
- Arithmetic functions & formula Calculations
- Communication functions with Remote I/O as well as Work
stations
- Closed loop PID control functions including nested and
cascaded loops.
- Output of PID controllers shall be 4-20 mA DC.
- Control valve position (in 4 20 mA) shall be made
available in PLC.
- PID Controller shall have auto tuning facility
- Totalisation of flow inputs.
- Linearisation function blocks and other useful function
libraries
- Linearisation function block shall be such that a table of
values (X against Y) can be entered in a menu driven
manner and for any particular field input X, the value of Y
can be calculated using the values of table by interpolation
method. Maximum 30 point linearisation function block
shall be considered. Below 30, point of linearisation shall be
user selectable.
- Built-in ambient temperature compensation for
thermocouple inputs from field.
- Broken sensor detection etc.
- Simulation facility / software shall be supplied for
programme testing without disturbing the working PLC .
- Minimum no. of PID Control Loops: 40.
- The complete PID blocks shall be transferred to HMI work
station in place of split bits .
- All computer shall have anti virus software.
The Software shall be suitable for PC based Programming Unit .

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2.0 Application
Programme
software
- Shall be as per process control requirement.
- The application programme software shall be written in
Ladder logic / block diagrams / statement form.
- Online programme editing facility shall be available.
- Troubleshooting manual for all application software, system
software, configuration, hardware, network, etc. to be
provided, spelling out possible causes, checks and
measures for corrective action.

3.0 HMI software - Window based, latest version (at the time of
implementation) of HMI software.
- HMI software package shall have the facility to perform
multitasking, data acquisition, supervisory control,
monitoring, control development and routine software.
- HMI software shall also have the features for alarming,
trending, data logging, production backup history, operator
action list , creation of shift reports after every shift, online
printing of events.
- Number of graphic pages shall not be a limit .
- HMI software shall have the facility of handling unlimited
tags (Digital as well as analog).
- HMI software shall be capable of curve fitting, co-relation &
regression functions.
- In the engineering workstation & servers, development
version of HMI software & Foundation Field bus system
software (licensed versions) shall be provided.
- In the operator workstations, runtime version of HMI
software & Foundation field bus system software (licensed
versions) shall be provided.

4.0 Database
Software
- ORACLE & DEVELOPER 2000 / As required & supported
by the system offered.
- All logging (data, event, etc.) of HMI in ORDBMS.
5.0 Operating System WINDOWS NT / 2000
(Service Pack Latest at the time of supply)

6.0 Testing - All tests on software, hardware, network, communication, etc.
shall be carried on the basis of a pre-agreed protocol clearly
listing out steps involved in testing with its responsibility and
minimum expected results as per specifications, engineering
and other documents.
- Purchasers involvement in design of control philosophy
development, application software and hardware combined,
drawing up of software specifications, software development,
off-line testing, etc. for both Level-I and Level-II system.
- Provisions to be made for off-line testing of Level-I and Level-
II systems prior to actual deployment.
7.0 Miscellaneous All software required for design, development, testing,
reporting-by-exception to be included. Troubleshooting,
simulation, etc. should be supplied with requisite number of
licenses.

06. Special tools and tackles for maintenance and troubleshooting :

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Test equipments, tools, software, etc. for all relevant hardware and/or software
systems/subsystems shall be provided .
Special tools to include tools in sufficient number for tracing, location, testing, jointing, fault
location & rectification, termination etc. for all cables including special cables (network and
FO cables) in all major units of the expansion projects.
Tenderer shall indicate the list of special tools and tackles .

07. Documentation :

All drawings, designs, configurations, software, numbers, models etc. listed in TS and
GTS are indicative and minimum only. Bidder may suggest a better and more
comprehensive solution.

08. Standardization :

- Minimum make / type shall be considered to minimize inventory.
- All automation hardware, including that employed in various machines, analyzers etc.,
from single manufacturer. No more than two models to be used for systems with more
than 24 I/Os. Both models to have same programming environment. All the hardware
in individual systems should be from the same product series. All the automation
hardware shall be interfaced to Ethernet network connecting the systems to HMI.

09. Training :

Training to be provided for at least the following levels:
Hardware of Automation System (PLC) and its programming & troubleshooting.
Training on Electro-Hydraulics Servo, proportional, etc.
HMI system configuration, programming & troubleshooting.
Client-server hardware, architecture, operating system, etc.
Fieldbus communication configuration, programming & troubleshooting.
Networking & communication systems Relevant toolkits, protocol analyzes, scopes,
loggers, etc., for maintenance and troubleshooting, to be included.
All the training to be conducted by OEM or its authorized training partner at a fully
equipped training center with facilities where extensive hands-on exercises can be
performed with system, identical to one under supply. Curriculum of each program to
be finalized in consultation with client. Required number of trainees (minimum 15) to
be covered through multiple programs on each topic. Most of the training to be
conducted before use. (number of trainees shall be as per commercial contract)

10. Conference Room Gadgets :

All the shops shall have a conference room in the new welfare building . Following
gadgets shall be provided in the conference room by the tenderer :-

In conference room, ceiling mounted projector with automatic screen and good
quality music system, also to be included. Projector and music system also to be
interfaced thru AV switching unit to all the computers in the room.

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1.02.16 Large Screen Display System :-

Large screen display screen system shall be provided in the control room of the plant .
The display system shall have linear setup in the control room .
The display system shall consist of a matrix of rear projection modules for high overall
resolution, a controller unit based on either MS-Windows or Linux , and optional wall
management software. Rear projection modules shall have DLP (Digital Light
Processing) technology .

The system shall have following features :-
High resolution to show large applications with several video or RGB sources.
The system shall not be susceptible to environmental factors like heat, humidity, or
vibration, which can cause an image to degrade over time The system shall be
zero hassle and minimal maintenance. All components are carefully chosen to
provide high mean time between failure and minimal mean time to repair.
The system shall have excellent module to module color uniformity.
The system shall have high contrast image.
Modular Design
The system shall be able to deliver a highly reliable and superior quality image
display to the operator. The displays can be seamlessly integrated into any center.
The modular concept shall also be applied within each module. System shall have
separate fan- module, projection unit and illumination unit so that maintenance
from the rear of the system is very easy. Filter and lamps can be replaced from the
outside.
Image optimization
Builtin redundancy with hot standby configuration
On screen menus

Size of the display system shall be 5m (length) x 3 m (width) . Distance from the screen
to operator shall be minimum 5 metres . The cube configuration shall be considered
based on the above size of the screen . The display unit shall have following features :
Full viewing angle : 180 degrees .
Half gain angle(Horz. / vertical) : 35 deg. / 35 deg.
Seam size screen : less than 0.2 mm
Aspect ratio : 4 : 3
Operating condition :
Humidity : upto 90 % non condensing
Temperature : upto 50 deg. C.
Optical dimming with dynamic feedback : Yes
Power supply :- 240 V AC , 50 Hz.
EBU Colour triangle

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Inputs : Shall have all options of multi input module: DVI-D, DVI-I, Multi Sync RGB
input (VGA upto UXGA), Video Input (PAL, NTSC, SECAM)
Projection unit shall have : -
Single chip DLP technology .
High resolution
High contrast .
Egronomic luminance
Integrated optical dimmer

1.02.17. UNINTERRUPTED POWER SUPPLY

1.0 Basic particulars for design :-
(i) Input Voltage 415 V AC +10% & -15%, 3-Phase ,4 wire,
grounded neutral system with a symmetrical fault
level of 50 KA for 1 sec .
(ii) Input Frequency 50 Hz. +/- 6%
(iii) Output Voltage 240 V AC , 1-Phase / 415 V AC , 3-Phase
(iv) Output Voltage tolerance +/- 1%

(v) Output Frequency 50 Hz. +/- 0.1%
Internal clock synchronism shall be provided .
(vi) Output Voltage wave
form
Sine wave
(vii) Harmonic Distortion Less than 3% for individual harmonics
Less than 5% for total harmonics distortion
(viii) Voltage Distortion Less than 3% for 100% linear loads
Less than 5% for nonlinear loads
(ix) Phase Displacement 120 deg. +/- 1deg. for balanced load
120 deg. +/- 3deg. for unbalanced load
(x) Transient recovery Shall return to steady state condition in less than
100 msec . after a disturbance
(xi) Maximum ambient 50 deg.C
2.0 Basic details
(i) Duty type True online continuous
(ii) Reference standard Features and performance in line with IEEE 446
(iii) Overload 125% of the rated output for 10 minutes
150% of the rated output for 30 sec
(iv) Configuration With isolating transformer, rectifier, inverter unit
and necessary DC batteries
(v) Power device Inverter power circuit shall comprise of IGBT
using PWM control technique
(vi) Redundancy The system shall be of dual redundancy type in
hot standby mode
(vii) Static bypass Automatic static bypass and common DC battery
bank .
The load shall normally be fed from the inverter.

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In addition to static bypass switch , a manual
changeover switch (MCCB) of adequate rating
shall be provided to supply the load directly
(bypassing the rectifier/charger, inverter, and
static transfer switch) from the mains instead of
through the UPS system .
(viii) Maintenance bypass Maintenance bypass shall be provided in parallel
to the static bypass line with an isolation device .
The contacts of the isolation device shall be of
make before break type .
(ix) Battery bank Sealed maintenance free (SMF) batteries
shall be provided for the battery bank .
The batteries shall be housed in a separate
battery cabinet located adjacent to the UPS
panel.
The battery power pack shall include SMF
battery housed in a separate cabinet . Battery
cells shall be mounted on slide-out trays for
ease of maintenance.
A battery disconnect circuit breaker with
undervoltage release (UVR) shall be included
for isolation of the battery pack from the UPS
module.
The UPS shall automatically be disconnected
from the battery by opening the breaker when
the battery reaches the minimum discharge
voltage level.
Casters and leveling feet shall also be
provided with the battery power pack cabinet
for ease of installation.
The battery bank shall be installed in separate
panel beside the UPS panel in the
airconditioned environment located in the
control room itself .
(x) Battery backup Battery shall be suitable to maintain the power
supply for at least 30 minutes (throughout the total
duration) in the event of mains failure with rated
capacity of the UPS at full load
(xi) Battery management
system
UPS shall have latest Battery Management
System to charge / discharge the entire battery
automatically
(xii) UPS management UPS shall have latest UPS Management System
to load / unload the UPS automatically .
(xiii) AC DB Necessary distribution board for distribution of
power from UPS output to individual consumers
(xiv) Loading capability UPS shall be capable of taking 100 % non linear
loads
(xv) Interchangeability of sub
assemblies
The UPS shall be constructed of replaceable
subassemblies. PCB's shall be plug-in type . Like
assemblies and like components shall be
interchangeable
(xvi) Noise level Maximum noise level shall be less than 60 dB at
a distance of 1 m from the body of the UPS

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(xvii) Efficiency The efficiency values of UPS under 50%
unbalanced load & 100 % linear loads shall be as
near as possible to normal efficiency
(xviii) Isolation transformer The isolation transformer shall be of dry type and
shall be provided on both input side , output side
and static bypass side of the UPS
(xix) Grounding The AC output neutral shall be electrically
isolated from the UPS chassis.
The UPS chassis shall have an equipment
ground terminal. Provisions for local bonding
shall be provided.
Component mounted doors shall be seperately
earthed through 2.5 sq.mm PVC insulated
green/green-yellow color flexible copper wire .
(xx) Communication port The UPS shall have inbuilt RS 485 port for display
of online status of UPS on HMI .
3.0 Rectifier

Dual rectifier with each unit rated for supplying
both inverter load and battery charger load in
different modes.
Rectifier unit shall consist of minimum six pulse
bridge connection .
Active front end rectifier set to reduce the
harmonic distortion .
With necessary smoothing reactor and filters
Automatic boost and float charging control.
Equalizing mode for compensating the charge
lost by the battery after a discharge automatic
changeover from equalizing mode to float
mode and vice-versa .
4.0 Protective features

Maximum current limiting .
Automatic reduction of current limit in the event
of cooling fan failure .
Boost charging and float charging current
limiting
Surge suppressor in output side of the UPS .
5.0 Inverter

With input circuit consisting of battery
contactor, battery filter and smoothing reactor .
DC/AC converter for voltage control .
Inverter proper and control electronics .
Series reactor and parallel filter .
Output transformer
6.0 Protection

Abnormal output voltage (over voltage & under
voltage) .
Abnormal link voltage .
Over current on output .
Over current on input or commutating failure .
Low battery voltage .
High transformer temperature .
Auxiliary supply failure .
Fan failure
Logic failure
Clock failure

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Fast acting HRC fuse for inverter circuit and
control circuit
Reverse power protection for parallel inverters .
7.0 Static by-pass switch

Static switch automatically switches the load to
the reserve power supply for the mains
whenever there is failure in inverter supply to
the load .
Fast acting inverter contactor shall connect the
inverter output to the load.
High speed fuses shall be provided for
protecting the thyristor against accidental
overload.
8.0 Indicating meters to be
provided on the ACDB
panel

Input voltmeter with selector switches .
Input ammeter with selector switches
DC voltmeter with selector switches
Centre zero type DC ammeter for
measurement of charging/discharging current
from the battery .
Digital type meters shall be provided for the
following :
AC output voltmeter with selector switch
Separate frequency meter to see Input and
Output frequency .
AC output ammeter with selector switch
AC voltmeter with selector switch for bypass
circuit .
AC ammeter with selector switch for bypass
circuit .
Frequency meter for bypass circuit .
9.0 MIMIC on UPS panels

MIMIC of the system power flow diagram as
single-line diagram of the UPS shall be
provided on UPS panels front door with long-
life LED's integrated within the single line
diagram to indicate the operating status of
different components/sections of the UPS.
10.0 Display and Operating
system

The UPS shall be provided with a
microprocessor based keypad and display unit
mounted on UPS panels front door for
operating and viewing the UPS status for
convenient and reliable user operation .
The monitoring functions such as metering,
status and alarms shall be displayed on an
alphanumeric LCD display.
Additional features of the monitoring system shall
include:
Menu-driven display with text format
Real time clock (time and date)
Alarm history with time and date stamp
(minimum upto 16 faults in memory with FIFO
sequence)
Battery back-up memory / condenser charged
back up memory .

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11 Metering

The following parameters shall be displayed:
Input AC voltage line-to-line and line-to-neutral
for each phase .
Input AC current for each phase
Input frequency
Battery voltage status
Battery charge/discharge current
Output AC voltage
Output AC current
Output frequency
Percent of rated load being supplied by the
UPS
Battery time left during battery operation .
12 Alarm Messages

Input power out of tolerance
Input phase rotation incorrect
Incorrect input frequency
Charger in reduced current mode
Battery charger problem
Battery failed test
Low battery voltage warning or blown battery
fuse
High battery voltage
DC bus overvoltage
Bypass frequency out of range
Load transferred to bypass
Excessive retransfers attempted
Static switch failure
UPS output not synchronized to input power
Input power single phased
Input voltage sensor failed
Inverter leg overcurrent in X-phase
Output undervoltage
Output overvoltage
Output overcurrent
System output overloaded
Load transferred to bypass due to overload
Fan failure
Overtemperature shutdown
An audible alarm shall be provided and
activated by any of the above alarm conditions.
13 Status Messages Normal operation
Load on maintenance bypass
Load on UPS
Load on static bypass
System shutdown
UPS on battery
14 Controls

UPS start-up / shutdown shall be done by push
button / rotary control switch
Normal operation / bypass operations shall be
done by a single rotary control switch.
An advisory display and menu-driven user
prompts writeup sticker (pasted inside the

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lJU o 2U5
panel door) shall be provided to guide the
operator through system operation without the
use of additional manuals.
Pushbuttons shall be provided to display the
status of the UPS and to test and reset visual
and audible alarms.
15.0 Constructional features The UPS system shall consist of a dedicated
ACDB panel consisting of Incoming and Outgoing
terminal blocks, MCCBs, power and auxiliary
contactors, isolation transformers.
(i) Isolation devices

MCCB (upto 630A) in incoming side
TPN/SPN MCB (of adequate rating) in outgoing
side.
Power circuit isolation device to have pad
locking in the OFF position with the door closed
(ii) Installation Metal clad , indoor installation
(iii) Mounting Floor mounting with base channel of ISMC-75
(iv) Enclosure protection Totally enclosed dust and vermin proof.
IP - 42
(v) UPS housing

Each UPS system shall be housed in a
separate cubicle, complete with an individual
front and back access door with concealed type
hinges.
For UPS panel all the switches, indication
lamps and meters shall be flush mounted on
the respective compartment door.
For ACDB panel the input MCCBs and output
MCBs shall be operated from outside the panel
door .
(vi) Back access Each panel shall have a door on back side . All
the doors shall have neosprene gasket .
Natural rubber gasket shall be provided
between adjacent panel doors and removal
covers .
(vii) Lifting hooks Lifting hooks for each panel shall be provided
(viii) Designation plate for
UPS
Inscription plate for each panel :-
Name plate shall be provided at top centre of
the UPS panel .
Name plates will be of Anodised Aluminium
with white letters engraved on black
background and in English language.
Letter height for UPS designation plate shall be
in the range of 25-50 mm .
Individual components shall be identified with
identification plate and shall match with the
identification tags mentioned in the drawing .
Danger board shall be provided on front and
rear side of the UPS both in Hindi , English
languages.
(ix) Thickness of sheet
steel (CRCA)
Load bearing members : 2.0 mm
Non load bearing member : 1.6 mm

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(x) Door earthing Hinged door at front and back with flexible
earthing connection .
(xi) Cable entry Incomer :- Bottom cable entry
Outgoing :- Bottom cable entry
(xii) Gland plates Undrilled removable bottom gland plates
( 3 mm thick)
(xiii) Output power
indication
Auxiliary contactors shall be provided in output
side of the UPS for potential free contacts for
indication of UPS and non UPS power supply
at different location .
Proper transducers shall be provided for
voltage and frequency indication at different
locations .
(xiv) Cooling of panels Panels shall have fan installed vertically at top
for forced air draft and louvers with screen
protection in bottom .
Fans shall be powered from input supply of the
UPS . Low velocity fans shall be used to
minimize audible noise output .
The thermal design, along with all thermal and
ambient sensors, shall be coordinated with the
protective devices before excessive component
or internal cabinet temperatures are exceeded.
The UPS shall be installed in air conditioned
environment.
(xv) Bolts , nuts & cable
glands
All bolts and nuts for terminations shall be
cadmium coated .
Double compression cable glands for receiving
external power & control cables.
Compartment door interlocked with the
isolating device for safety with provision for
defeating it by authorised person
(xvi) Indicating lamps All indicating lamps shall be of LED cluster high
density type.
(xvii) Finish Interior and exterior :- RAL 7035
(xviii) Terminal block Terminal block for incoming cable shall be
located in back side and outgoing cables shall
be in front side of the ACDB panel .
All incoming terminal blocks shall be fully
insulated for the working voltage.
The terminal blocks shall be sleeved color
coded Red , Yellow , Blue , Black for R,Y,B,N
respectively using heat shrinkable PVC sleeve .
All outgoing terminal blocks shall be sleeved
color coded Red and Black for line and phase
respectively using heat shrinkable PVC sleeve .
Colour coding shall be provided for TBs and
wires for different voltages level .
All the terminal blocks shall be shrouded .
Not more than two connections shall be made
at one terminal.
Terminal blocks shall be suitable to connect

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two cores of minimum 2.5 sq.mm .
There shall be 20 % spare terminal blocks

(xix) Minimum air clearance
for bare busbars .
Phase to phase :- 25.4 mm
Phase to earth :- 19.0 mm

(xx) Output power bus The solid output power bus shall be of bare
copper with a minimum rating of 100 A at 240
V AC (1 pair).
(xxi) Earth bus The main earth bus shall be of 50 x10 mm GI
with extension at both ends of switchboard for
connection to safety grounding network . Earth
busbar shall run continuous throughout the
UPS panel at bottom .
(xxii) Panel internal wiring The panel internal wiring shall be carried out by
1100 V grade , single core , black color PVC
insulated , stranded copper wire of following size
Current transformer circuit :- 4.0 sq.mm
Control and potential circuit :- 2.5 sq.mm
Identification of wire shall be numbered by
plastic/ ceramic ferrules.
Ferrules shall be self locking type.

(xxiii) Incoming Feeders 3 pole MCCB.
Ammeter with 4-position selector switch (three
phases & OFF)
Voltmeter with 4-position selector switch and
fuses (three line-line & OFF)
Current transformers (for metering)
3 nos. indicating LED type lamps (R,Y,B)
3 nos. indicating LED type lamps (CB ON-Red ,
CB OFF- Green, CB TRIP - Amber)
Following protections are required for the
MCCB controlled
Incomers :-
- Overcurrent releases .
- Short circuit .
- Earth fault .
(xiv) Outgoing Feeders Each outgoing feeder shall have followings:-
Outgoing feeders shall have SPN MCB
MCB of 09 kA rating with Thermo-magnetic
releases .
(xv) Testing All routine tests shall be as per IS-8623 (Part-II)
1993
Type test certificate shall be submitted.
(xiv) Documentation Operation & maintenance manual
Wiring diagram (internal panel showing
individual components and flow of wires .

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1.02.18 Electronic Weighing System

This section covers electrics for belt weigh feeders, loss in weigh feeders, load cell
based bunker level measuring system & belt weigh scales.

1.1 Microprocessor based Individual Weighing Controller (IWCs) with digital display and
keyboards for Belt weigh feeders/ Loss in weigh feeders

1.2 VFD drive for speed control of AC motors of belt weigh feeders with necessary
switchgears, incoming choke, output reactors if required, protective devices,
communication links with IWC, input/output for remote start/stop, interlocking,
indication lamps, controls, metering, potential free contacts for remote status indication
like ON/OFF/TRIP/ converter fault (to be wired to PLCs), motor protective devices at
field etc. Technical features of VFD drive shall be as per General specification for
electrical system(GS-03).

1.3 Individual Belt Weigh feeder panels housing IWC (Intelligent weighing controllers)
controller & VFD drive, DOL starters for vibrating hoppers interlocked with belt weigh
feeders.

1.4 Microprocessor based Bin weight measuring panels with digital display and keyboards
with auto taring and auto calibration facility. Bin Measurement panels housing IWC
controller (IWC Controllers for mote than one Bin can be combined in one panel.

1.5 Beltweigh scale panels (if any as per Mechanical scope) housing microprocessor
based measuring indicator with digital display and keyboards with auto taring and auto
calibration facility.

1.6 Provisions for Communication with PLC / DCS .

Belt Weight feeder IWC, Bin weigh measuring controller & Belt Weigh Scale IWC shall
be able to communicate 100% with purchasers PLC/DCS on the plant communication
bus as selected (like Profibus DP) by Tenderer.

1.7 Load cells, techogenerators, field junction boxes, limit switches etc. for Belt weigh
feeders, Bin level measuring systems, Belt weigh scales (if any).

1.8 Common local control station for Belt weigh feeders & Vibrating hoppers (as
applicable) housing Local /Off/Auto selector switches, Start/stop push buttons, speed
increase/decrease, TPH indicators etc.

1.9 Local Indicator panels for Bin weighing control & Belt weigh scales (if any)

1.10 LT AC motors for belt weigh feeders & vibrating hoppers.

1.11 Calibration weights for belt weigh feeders.

1.12 Supply of dummy load cells for various Bunkers (BLMS system)

1.13 Features for Belt slip detection in case of weigh feeders, like tail end tacho or other
suitable measures shall be provided by Tenderer.

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2.1 DESIGN BASIS FOR BELT WEIGH FEEDER/LOSS IN WEIGH FEEDER

The weighing system shall be designed, manufactured, assembled and tested in
accordance with relevant OIML/NTEP Standard . Equipment shall comply with statutory
requirement of Weights & Measures Deptt. Govt. of Chhatisgarh and Govt. of India .
The equipment shall be of proven designed, imported and reputed make.

The consistency of the feed rate shall be guaranteed within +/- 0.5% of the set value
within the operating range of 10% to 100% of rated capacity.

The weighing control shall be totally automatic with close loop control. The feed rates
of different materials shall be calculated by the computer and set points of Belt weigh
feeder shall be set by the computer through PLC. In case of computer failure manual
setting (remote manual) and operation of feeders shall be possible.
Load cell shall be globally reputed make, confirming to OIML/NTEP Standard and
preferably digital type, side mounted and easily replaceable type.
Weighing system shall be mounted in the horizontal portion of the conveyor with multi
idler/weigh carriage system.
Equipments shall be provided with anti sway, anti sagging and anti slip devices.
Auto zero track, annunciation and diagnostic facility shall be provided.
Surge, radiation, EMF & RF protection devices shall be provided.
Test weights for different range of calibration should be provided with each equipment.
Redundant electronics shall be provided.
Special tools & tackles shall be provided with the equipment. Such as HBM/Molen load
cell calibrator 2 nos., Portable think Pad based software programmer 2 nos.
Universal Source HP/Fluke 2 nos. High precision Digital Multimeter minimum 4
digit Philips/ HF/Fluke 2 nos. Professional Toolkit RS 2 nos. Quard, Triple output DC
Power supply make ISO Tech 2 nos. WMD1 Multi Digital Power Unit with Soldering
Station, make Weller 2 nos. USB to 2xPS/2 Converter alongwith USB IrDA Infrared
Adaptor 2 nos.
Two years maintenance spares shall be included.
Compress air and high pressure water injection facilities to be provided for cleaning of
weighing area.
Training on maintenance aspect is required for Inst. & Weighment personnel.

2.2 CONTROLLER PANELS OF BELT WEIGH FEEDERS/LOSS IN WEIGH FEEDER
PANEL

The IWCs for control of Belt weigh feeders/ LIWs shall be microprocessor based
having automatic weighing and calibration facilities. The system shall be complete with
protection against overloading. Accuracy of Belt weigh feeders shall be +/-0.5% or
better of preset feed rate.

It shall be possible to operate the Belt weigh feeders under the following modes:

Local - Volumetric
Local - Gravimetric
Remote - Gravimetric (remote manual/PLC automatic)

Under remote mode of operation, following control shall be possible.

Remote - From IWC panel
Remote- From HMI station at individual shop control room.

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Microprocessor shall be provided with each IWC as per standard design/ system requirement. IWC
shall generate signal for material feed rate in t/hours. The IWC shall compare the actual feed rate
with the set point feed rate and generate a suitable correction for the VVVF converter of belt drive.
The signal shall change the belt speed and accordingly provide the desired feed rate. It will be
complete with auto calibration, auto tare, auto belt slip/ drift monitoring facilities etc. The stored
values after calibration shall not change due to power failure.

Belt Weigh feeder panel housing above IWC & VFD drive shall also be provided with following
control equipment /facilities.

- Main incoming MPCB/MCCB (50kA) for incoming power supply
- Control transformer (415/110V) with MPCB (50kA) at primary, MCBs at secondary.
- MPCB, Power contactor (min. 25A), thermal overload relay, necessary auxiliary contactors,
ON/OFF/TRIP indication lamps for each motor of bin vibrating hoppers.
- Necessary Power supply units, conversion equipment.
- DP MCBs for incoming UPS power supply and its distribution to all panels.
- Panel illumination lamps (fluorescent tubular).
- Start/stop push button, selector switches as required.
- Power ON indication.
- Power and control terminals.

The IWC shall have following features (minimum)

- Actual flow rate indicator.
- Set rate feed indicator.
- Totalised amount indicator.
- Belt load indicator.
- Belt speed indicator.
- Deviation indicator.
- Fault messages (separate lamps).
- Operational mode selector switch for gravemetric/volumetric/calibration/ Automatic and
Constringency mode selection.
- Auto taring & calibration.
- Load cell/Tacho filter time
- No motion alarm set.
- Material starvation signal
- Load sensor break
- Material over/under load alarm
- Gravimetric / volumetric deviation alarm
- Proportional band, Integral time, Derivative time (for Gravimetric / volumetric mode) for PID.
- Tantalizer value
- Tare value
- Load electrical value
- Speed electrical value

Following displays and messages shall be possible for all the operating and calibrating
functions:

- Set point.
- Normal/Maintenance/Calibration modes.
- Actual feed rate.
- Belt load (Platform load).
- Belt speed.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lJb o 2U5
- Totaliser value.
- Deviation error between set and actual feed rate.
- Service data such as measured value, controller output, control signal level etc.
- Event messages/fault messages.

The above shall be available on each IWC on digital display unit in central control room.
Display and messages listed above shall also be made available on VDU of PLC/DCS.

Panel Construction features.

- Floor mounted, free standing.
- Dust and vermin proof.
- CRCA sheet steel clad.
- Minimum 2.0 mm thick for panels.
- Suitable to withstand vibrations to be encountered in steel plant applications.
- Cubicles with illumination lamps door switches, space heaters and adequate sockets for
soldering.
- All control blocks plug-in-type with necessary test sockets.
- Units shall be self contained and serviceable.
- Power wiring-Min 2.5 sq.mm. Cu
- Control wiring Min 1.5 sq.mm. Cu
- The panel door shall be provided with toughened glass in front of controllers for viewing of
display units without opening the panel door. All control devices and indicators shall be
mounted on the front. Two numbers earthing studs shall be provided with the panel for external
earthing. All power, control, and signal terminals of different voltages shall be segregated. 20%
spare terminals shall be provided in the panel.

3.1 BIN/WEIGH HOPPER LOAD CELLS AND LEVEL MEASURING SYSTEM:

Design Basis for Bin Level Measuring System

Equipment shall comply with statutory requirement of Weights & Measures Deptt. of Govt. of India.
Load cell shall be of globally reputed make, confirming to OIML/NTEP Standard & preferably digital
type. Load cell shall be easily replaceable type, provided with safely devices from impact load, vibration
and lifting arrangement facility. Lightning & Surge protection devices shall be provided in load cells,
JBs, electronics & main electrical power supply.
Load cells shall be of high precision strain gauge type, hermetically sealed, robust in design, shock proof
and insensitive to overload, temperature, vibration, electrical noise etc. Enclosure class shall be IP 67 /
IP 68 .
Load cell shall be provided with ambient temperature compensating device upto 55 deg. C.
Provision shall be kept to neutralise the error caused due to application of transverse forces.
Max. Measurement error permitted is +/- 1%
Weighing system shall be auto zero & auto calibration facilities.
Test weight for calibration shall be provided.
The weighing system shall be hooked up with customer host computer and shall support remote
monitoring on BSPs Existing Plant Wide Network.

3.2 CONTROL PANEL FOR BIN LEVEL MEASUREMENT (BLM)HOUSING IWC

Bin level measurement system shall be microprocessor based having automatic weighing, taring and
necessary calibration facilities. The system shall be complete with protection against overloading.
Accuracy of weighing +/-0.1% or better.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lJ? o 2U5
The controller shall have digital display and keyboards, indication, alarm, annunciation etc. It will be
complete with auto calibration, auto tare facilities etc. The stored values after calibration shall not
change due to power failure.
The controller shall be complete with built in power supply unit, CPU, program memory, A/D & D/A
converters, etc. The above will be of modular design using standard PCBs and connectors.
It should communicate actual weight/level, conditions for bin empty, level low, level high etc to
Automation system.
One no. large display unit for outdoor display shall be provided.
Compress air and high pressure water injection facilities to be provided in weighing area.

4.1 BELT WEIGH SCALES

The IWPs for control of belt weigh scales shall be microprocessor based having automatic weighing and
necessary calibration facilities. The system shall be complete with protection against overloading.
Accuracy of belt weigh scale shall be +/-0.25% or better of flow rate.

Microprocessor as per standard design/ system requirement shall be provided each IWC. Microprocessor
shall multiply load cells and conveyor speed signal in digital form to generate signal for material
conveying rate in T/Hours. It will be complete with auto calibration, auto tare etc. The stored values after
calibration shall not change due to power failure.

The following displays and messages shall be available for all the operating and calibrating functions:

Conveying rate in TPH.
Belt load (Platform load)
Belt speed.
Totaliser value.
Service data such as measured value, controller output, control signal level etc.
Event messages/fault messages.
Auto taring & Error corrections.

The above shall be available on each IWC on digital display unit. Display and messages listed above will
be made available on VDU of in central control room.

Panel Constructional feature

Shall be same as for Weigh feeder panels.

5.0 DIGITAL TECHGENERATORS

It will be of robust construction and designed to give guaranteed accuracy of feed rate. It shall generate
consistent output pulses of positive or negative polarity as applicable by accepting shaft rotation. The
output pulses shall be suitable for feeding into high impedance electronic circuit/instrument for digital
measurement and control. The enclosure class shall be IP 67. It will be provided with ambient
temperature compensating device.

Arrangement of mounting of techogenerators and its coupling with AC motor shall be decided
considering ease of maintenance.

6.0 LOCAL CONTROL BOX (LCB) FOR BELT WEIGH FEEDERS/LOSS IN WEIGH FEEDER &
LOCAL INDICATION BOXES FOR BLMS & BELT WEIGHERS.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lJS o 2U5

Each belt Belt weigh feeder/Loss in weigh feeder shall be supplied with a local box with following
features.

- Sheet steel (2.0mm thick) construction.
- Wall/ structure mounted type.
- Hinged door, dead front type.
- Enclosure class IP-55.
- To be painted as per standard procedure agreed.
- Internal wiring with 1.5 sq.mm copper conductor.
- The box shall be wall/structure mounted type and be complete with cable glands and lugs.

The LCB shall be provided with the following :

- Local Off Remote selector switch.
- Start/Stop push buttons
- Emergency stop push button (press to lock turn to release type)
- Increase/decrease PB for speed setting
- Feed rate actual (TPH meter digital type).
- Start/stop push button for bin vibrator
- Indication lamps.
- Any other device required for satisfactory operation of BWFs to be decided during detailed
engineering.

Each local indication box for BLMS/Weigh Scales shall have digital indication of Bunker level/feed rate.

7.0 LOAD CELLS

- Load cell shall be imported reputed make as per OIML / NTEP standards with surge protection.
- Compression type suitable for weigh hoppers and material presence detectors on charging
conveyor.
- Enclosure class IP 67 / IP68
- Hermetically sealed, stainless steel precision strain gauge / digital type.
- Maximum usable load: 200%
- Destruction load: >500%
- 300% over load capacity.
- Suitable for maximum 70C.
- Temperature compensation range: - 40C to 70C
- Capacity of the Load cell for BLMS system shall be as per details given under mechanical part.
However, final rating of load cells shall have safety margin of minimum 150% of the rating
calculated.
- Load cell accuracy 0.04%
- Combined error: 0.03%
- Excitation: 10 to 50 V dc
- Zero balance: 1% of R.O.
- Insulation resistance: >5000M
- Complete with excitation source, transmitter, amplifier, junction boxes, special cables, etc.

1.02.19 CABLES :
1. HT Cables
(i) 11 kV (UE) XLPE cables

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Sl.No. Parameter Description
1.0 Voltage Grade 11 kV (UE)
2.0 Duty type Heavy duty
3.0 No. of cores 3 cores
4.0 Reference standard IS:8130 1984
IS:5831 1984
IS:3975 -1988
IS:1554, part - 1, 1988
IS:3961 (Part-II) - 1967.
IS:7098 Part-I & II
IEC-60502
5.0 Conductor type Compact circular stranded (rm/V) aluminum
conductor, with conductor screening of extruded semi
conducting material . Conductor construction class-2
as per IS 8130-1984.
6.0 Insulation type XLPE insulated and insulation provided with shielding
of extruded semi conducting compound over individual
core followed by lapped semi conducting material and
copper tape (non magnetic) metallic screen , cores
stranded together with a holding tape provided with a
common covering of extruded inner sheath of type
ST2 compound .
Thickness of the insulation shall be 5.5 mm for size
3x185 sq.mm as per table-2 IS 7098 (part-II) 1985.
7.0 Armour Galvanized steel wire armoured .
For multi core cables , armouring shall be applied over
the inner sheath by flat steel wires strips( formed wire).
Round steel wire armouring can also be offered.
For single core armoured cables non-magnetic armour
consisting of hard drawn flat or round aluminium wires
shall be provided.
8.0 Outer sheath Overall PVC outer sheath of type ST-2 compound as
per IS 5831/1984. Outer sheath should be applied
with extrusion only cables to be ISI marked.
Thickness of the outer sheath shall not be less than
3.6 mm for size 3x185 sq.mm as per table 5 of
IS:7098 )part-II)/1985 & IS:10462 (part-I)/1983). The
sheath shall be black in colour .
Suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable
against rodent and termite attack.
9.0 Miscellaneous Copper screen shall be suitable to carry 1 KA E/F
current for one second.
10.0 Temp. rise on continuous
load
90 deg.C
11.0 Oxygen index of outer sheath
material for XLPE Cable
Shall not be less than 29 at 27 2 deg. C.

12.0 Temperature index Not below 250C.
13.0 Max. conductor withstand
temperature during short
circuit.
250C

(i) 6.6 kV (UE) XLPE cables

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1.0 Voltage Grade 6.6 kV (UE).
3.0 No. of cores 3 cores
IS:5831 1984
IS:3975 -1988
IS:1554, part - 1, 1988
IS:3961 (Part-II) - 1967.
IS:7098 Part-I & II
IEC-60502
5.0 Conductor type Compact circular stranded (rm/V) aluminum conductor,
with conductor screening of extruded semi conducting
material . Conductor construction class-2 as per IS 8130-
1984.
6.0 Insulation type XLPE insulated and insulation provided with shielding of
extruded semi conducting compound over individual core
followed by lapped semi conducting material and copper
tape (non magnetic) metallic screen , cores stranded
together with a holding tape provided with a common
covering of extruded inner sheath of type ST2 compound .
Thickness of the insulation shall be 5.5 mm for size 3x185
sq.mm as per table-2 IS 7098 (part-II) 1985.
7.0 Armour Galvanized steel wire armoured .
For multi core cables , armouring shall be applied over the
inner sheath by flat steel wires strips( formed wire) .
Round steel wire armouring can also be offered.
For single core armoured cables non-magnetic armour
consisting of hard drawn flat or round aluminium wires
shall be provided.
8.0 Outer sheath Overall PVC outer sheath of type ST-2 compound as per
IS 5831/1984. Outer sheath should be applied with
extrusion only cables to be ISI marked. Thickness of the
outer sheath shall not be less than 3.6 mm for size 3x185
sq.mm as per table 5 of IS:7098 )part-II)/1985 & IS:10462
(part-I)/1983). The sheath shall be black in colour .
Suitable chemicals shall be added into the PVC compound
of the outer sheath to protect the cable against rodent and
termite attack.
9.0 Miscellaneous Copper screen shall be suitable to carry 1 KA E/F current
for one second.
10.0 Temp. rise on continuous
load
90 deg.C
11.0 Oxygen index of outer
sheath material for XLPE
Cable
Shall not be less than 29 at 27 2 deg. C.

12.0 Temperature index Not below 250C.
13.0 Max. conductor withstand
temperature during short
circuit.
250C

2. LT CABLES

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(i) 1.1 kV Power Cable

1.0 Voltage Grade 1.1 kV grade
3.0 No. of cores - 3.5 / 4 core cables shall be used for motor feeders.
- For other consumers or for power supply to other
panel 4 core (upto conductor size of 50 sq.mm) or 3.5
core (for conductor size beyond 50 sq.mm) cables
shall be used.
IS:5831 1984
IS:3975 -1988
IS:1554, part - 1, 1988
IS:3961 (Part-II) - 1967.
IS:7098 Part-I & II
IEC-60502
5.0 Conductor type - Pain aluminium conductor.
- All power cables of size 10 sq.mm and above shall
have standard sector shaped (sm) or compact
circular stranded (rm/V) or circular stranded (rm)
aluminum conductors as applicable.
- The conductors will be H2 or H4 grade.
- The solid conductor shall be class - 1 and the
stranded conductor will be class - 2.
- The conductors shall be solid for conductor of
nominal area upto and including 6 sq. mm. and
stranded beyond 6 sq. mm. Conductors of nominal
area less than 25 sq. mm. shall be circular or shaped.
Cables with reduced neutral conductor shall have
sizes as per Table 1 of IS 1554 (Part-1) -1988.
6.0 Insulation type - XLPE insulation
- The insulation compound shall be conforming to
IS:7098 (Part I) - 1988.
7.0 Inner sheath - For armoured / unarmoured cables a tough inner
sheath of heat resisting PVC compound (wrapped /
extruded as per size) ,Type ST2 as per IS 5831 .
- Black in colour .
8.0 Armour - Galvanised steel wire armour shall be used for 3Cx10
sq.mm / 4Cx6 sq.mm cable.
- Galvanised flat steel wires (strips) armour shall be
used for bigger size cables.
- Single core armoured cables are provided with non-
magnetic armour consisting of hard drawn flat or
round aluminium wires.
9.0 Outer sheath - For armoured / unarmoured cables a tough outer
sheath of heat resisting PVC compound (Type ST2
as per IS 5831) .
- Black in colour .
10.0 Miscellaneous - Minimum cross - sectional area of the power cable
shall be 6 sq.mm in case of aluminium conductor and
2.5 sq.mm in case of copper conductor.

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- Power cables shall be selected from core sizes of 6,
10, 16, 25, 50, 70, 120, 150, 240 & 300 sq.mm
(Aluminium conductor).
11.0 Temp. rise Shall be limited to 90 deg.C.
12.0 Core identification - Cable identification will be provided by embossing on
the outer sheath the following:
Manufacturers name & trade mark
Voltage grade
Year of manufacture
Type of insulation
- R,Y,B for phases .
- Black for neutral (fourth core)

(ii) 1.1 KV Grade Control Cable :-

3.0 No. of cores As per requirement .
IS:5831 1984
IS:3975 -1988
IS:1554, part - 1, 1988
IS:3961 (Part-II) - 1967.
IS:7098 Part-I & II
IEC-60502
5.0 Cross sectional area Shall be 1.5 / 2.5 sq.mm. (as per TS)
6.0 Conductor type Solid annealed circular stranded copper conductor.
7.0 Insulation type XLPE insulated
8.0 Inner and outer sheath - Type ST-2 PVC shall be used for inner sheath .
- Type ST-2 PVC shall be used for outer sheath .
- Both inner and outer sheath shall be extruded type upto
7 core and after 7 core inner sheath shall be wrapped ..
9.0 Armour - Galvanised steel wire armour shall be used for cables
upto 14 cores .
- For cables having larger number of cores galvanised
formed wire (steel strip) shall be used.
10.0 Spare Cores - 3, 5 and 7 cores cables shall have at least one spare
core, cables with 10 core and above shall have at least
2 spare cores.
11.0 Miscellaneous - The Tenderer shall furnish necessary calculations to
show that the selected cable satisfy the criteria
including for voltage drop.
- Cables for temperature detectors shall be screened
type of required technical parameters with core size not
less 1.5 sq.mm.
Voltage grade
Year of manufacture
Type of insulation
- Cores of the cables upto 5 cores shall be identified by

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colouring of insulation.
- For cables having more than 5 cores, core identification
shall be done by numbering insulation of core
sequentially.
- All the numbers shall be of same colour, which shall
contrast with the colour of insulation.
- Numbers shall be written in figures and words both
- The numerals shall be legible and indelible.
- The numbers shall be repeated at regular intervals
along the core, consecutive numbers being inverted in
relation to each other.
- When number is a single numeral a dash shall be
blacked underneath.
- If the number consists of two numerals, these shall be
disposed one below the other and a dash placed below
the lower numeral.
- The spacing between consecutive numbers shall not
exceed 100 mm.

(iii) 1.1 KV Grade Screened /Special Cable :-

3.0 No. of cores As per requirement .
4.0 Cross sectional area Shall be 1.5 sq.mm.
5.0 Conductor type - Solid annealed circular stranded copper conductor.
- For twisted pair cables , the conductors shall be of
stranded tinned copper having proper flexibility to
provide limpness and extended flex-life as required for
these small diameter cables.
6.0 Insulation type - PVC insulated, Type A
- Type ST-1 PVC shall be used for inner sheath.
- Both inner and outer sheath shall be extruded type.
- Outer sheath made of PCP (Chloroprene rubber),
abrasion resistant, oil resistant and flame retardant
conforming to IS:434 1964 (Part - I), as amended upto
date.
7.0 Screen - Tinned annealed copper mesh over metallised tape , in
a close woven braid .
8.0 Shielding - Special aluminium foil to provide 100% shield coverage
for optimum protection against radiated interference
and ingress of audio and radio frequencies.
- It shall have shorting fold for metal to metal contact and
isolation fold to prevent adjacent shields from shorting
to one another, so as to improve the voltage breakdown
characteristics. The drain wire shall be of stranded
tinned copper wire of 0.518 sq. mm. (20 AWG) cross-
section.

9.0 Spare Cores - 20% spare cores but not less than 2 spares shall be
provided in all the multi core cables .
10.0 Reference standard As per relevant IS with latest amendments

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11.0 Miscellaneous - The Tenderer shall furnish necessary calculations to
show that the selected cable satisfy the criteria
including for voltage drop.
- Cables for temperature detectors shall be screened
type of required technical parameters with core size not
less 1.5 sq.mm.
- The special twisted paired cables shall be of the type to
provide balanced signal transmission and shall have
good noise immunity.
Voltage grade
Year of manufacture
Type of insulation
- Cores of the cables upto 5 cores shall be identified by
colouring of insulation.
- For cables having more than 5 cores, core identification
shall be done by numbering insulation of core
sequentially.
- All the numbers shall be of same colour, which shall
contrast with the colour of insulation.
- Numbers shall be written in figures and words both
- The numerals shall be legible and indelible.
- The numbers shall be repeated at regular intervals
along the core, consecutive numbers being inverted in
relation to each other.
- When number is a single numeral a dash shall be
blacked underneath.
- If the number consists of two numerals, these shall be
disposed one below the other and a dash placed below
the lower numeral.
- The spacing between consecutive numbers shall not
exceed 100 mm.

(iv) Heat resistant cable

1.0 Voltage Grade 1.1 kV grade confirming to IS: 9968 (Part-II)- 1988
2.0 Reference standard IS: 6380
4.0 No. of cores Single or multicore as per requirement
5.0 Cross sectional area As per requirement .
6.0 Conductor type Annealed tinned copper conductor
8.0 Insulation type Silicone rubber insulation
9.0 Shielding Asbestos or glass braid and lacquered protection
11.0 Outer sheath Flame retarded
Oil resistant
12.0 Miscellaneous As per requirement for working at higher temperature,
nickel coating shall be done .
13.0 Armouring GI strip armoured as per requirement (as specified in

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respective TS)

(v) Trailing cable
1.0 Voltage Grade 1.1 kV grade confirming to IS: 9968 (Part-II)- 1988
2.0 Reference standard IS: 9968
IS: 8130
IS: 6380
6.0 Conductor type Highly flexible stranded tinned annealed high conductivity
copper conductor
8.0 Insulation type EPR (Ethylene-propylene Rubber)
For higher temperature zone, silicone rubber (trailing duty)
9.0 Shielding Each individual core protected and covered and overall
11.0 Sheath Poly-chloroprene rubber or chlorosulphorated polyethelene
cable shall be conform to IS: 9968 (Pt-I) - 1988.
Flame retarded (for higher temperature area)
Oil resistant
12.0 Miscellaneous Shall have one additional core for earthing .
13.0 Armouring GI wire armoured as per requirement and size (as
specified in respective TS)

(vi) Flame Retardant Low Smoke (FRLS) Cables
2.0 Reference standard Category AF as per IS : 10810
ASTM-D 2863 (Critical Oxygen Index)
ASTM-D 2863 (Temperature Index)
ASTM-D 2843 (Smoke density)
IEC 754-1 (Acid gas generation)
IEEE-383 (Flammability test on group of cables)
Swedish chimney test SS 424175, class F3. (Flammability
test)
IEC 332-1 (Flammability test)
IEC 332-3 (Flammability test)
IS 5831 (Fire resistant test)
6.0 Conductor type Annealed tinned copper conductor
8.0 Insulation type XLPE insulation
11.0 Sheath Specially designed with thermoplastic or thermosetting
materials , superior resistance to ignition and flame
propagation with smoke emission and toxicity or corrosive
characteristics
Flame retarded
Oil resistant
12.0 Armouring GI wire / strip armoured as per requirement and size (as
specified in respective TS)
13.0 Test values Critical Oxygen Index : Minimum 29

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Temperature Index : Minimum 250 deg. C
Smoke density : Minimum average light transmission of
40%
Acid gas generation : HCl gas released 20% maximum
Flammability test on
group of cables : As per standards mentioned
Flammability test : As per standards mentioned
Fire resistant test : As per standards mentioned

01.02.20 EOT Cranes

01. Trolley lines and power supply arrangements for cranes (DSL System)

Power to all the bays shall be fed from crane LTSS through PDBs installed in respective
bays . Number of panels shall be decided as per requirement (to be indicated by the
tenderer . Isolator (MCCB) for each feeding section will be provided in each bay .

All the PDBs shall have 02 incomers and 01 buscoupler . Normally both the incomers will
be charged and buscoupler will be OFF . In case of power failure or any fault power will be
fed from either of the incomers . Incomers , buscoupler and busbars shall be designed to
take care of entire load of the cranes .

Crane trolley lines feeding cranes in major production units shall be sectionalized with two
separate feeding points. Two fully rated MCCB / ACB shall be provided for each incomer
feed point to crane DSL. Sectionaliser shall be provided between the two incoming ACBs
with necessary padlocking arrangement.
Isolator (MCCB) panels shall be provided for the repair section for maintenance by the
tenderer .

In case of circuit breaker rating more than 630A , ACBs shall be provided . All the ACBs
shall be installed in a PDB which shall in turn be installed in the bay / shop floor . In case of
circuit breaker rating is 630A or less , than the MCCB (as isolator) with earth fault
protection and magnetic over current release shall be mounted in the respective column of
the feeding bay in a separate enclosure at manheight level .

Signal lamps shall be provided just below the trolley lines at 60m intervals as well as at the
beginning and end of each section/repair section to indicate whether the trolley lines are
energized or not.

Insulation air gap between two sections of a sectionalised trolley line shall be minimum 50
mm for voltage levels upto 500V, but in no case should be greater than the length of the
current collector on the crane.

Maintenance Bay

When two or more cranes are fed from the same trolley line, maintenance bays (repair
sections) shall be provided with sectionalizing isolator so that repair or maintenance of any
crane can be carried out without disturbing the operation of the other cranes. Necessary
DSL arrangement for repair section shall be provided by Tenderer.

Isolator panels shall be provided for each repair section for maintenence. Dead zones shall

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be provided with isolator arrangements to prevent collision between cranes and momentary
paralleling to two incomer supplies. Incomer ACB's shall be provided with earth fault
protection and magnetic over current release. The DB,s shall be located suitably on the
shop floor.

For end zones, minimum length of maintenance bay shall be 2 m plus the crane width. For
middle zone, the length of hospital bay shall be 4 m plus the width of crane.

Repair section shall be provided with red lamp steady/flashing fixtures at four corners.
These fixtures shall be located at crane gantry with manual ON/OFF provision.

Boarding or access platform shall be arranged within the limits of each repair section for
approach to be crane.

02. Trolley power conductors

The Power conductors or down shop lead (DSL) shall have 4 conductors, 3 phase, 4
trolley line system ( 3 power + 1 earth) .
Trolley power conductors shall be of mild steel angel sections / rails .
For cranes/hoists upto 10 t capacity, the DSL shall have 50 x 50-x 6 mm MS angle. For
cranes above 10t upto 100 t, the DSL shall have 75 x 75 x 6-mm MS angles. For cranes
above 100 t, the DSL shall have to maintain rail size of 75 lb.
Expansion and section gaps shall be provided in rails at every 30m. The gaps shall be
cut at an angle of 30 degree to the rail and shall be 50mm wide. The gaps shall be
provided with flexible joints. The conductors shall be supported at 3000 mm intervals by
insulators mounted on brackets welded to crane girders.
Looping cables shall be used in parallel with the conductor rails and aluminium equalising
strips shall be provided, wherever necessary, for limiting the voltage drops. However,
aluminium equalising strips shall not be used in the hot areas like slag / liquid steel / slab
/ slab yard etc. In such areas, copper cable looping shall be used.
In order to provide electrical continuity across the expansion joints the power conductors
on both sides of the joints shall connected by stranded aluminum conductor jumper, fitted
with steel Aluminum strap and lugs suitable for the steel angle sections .
The power supply feeder and trolley line conductors/looping cables shall be selected so
as to limit the voltage drop to within 15% of the rated voltage at the crane motor
terminals for the short time peak current corresponding to the starting of the largest
capacity motor and the maximum continuous operating current of the rest on the system.
Expansion and section gaps shall be provided in rails at every 30m. The gaps shall be
cut at an angle of 30 degree to the rail and shall be 50mm wide. The gaps shall be
provided with flexible joints.
The section shall be straight, unbranded and smooth on the running surface. Joints
between lengths of angles shall be welded and all welds shall be finished flush with
parent metal. The conductors shall be painted with anticorrosive paint, except for contact
surface. Parallel aluminum buses shall be provided as specified. The jointing of standard

BHILAI STEEL PLANT


lengths shall be made by 100% but welding and top surface finished smooth by grinding
to get free movement of the current collectors.

03. Insulators and trolley line holders

The insulators used for the manufacture of trolley line holders shall be preferably steatite,
tufnol or porcelain insulation material having substantial mechanical strength specifically
against blows and vibrations. They shall be capable of withstanding the impact and shocks
resulting from operation of the machine. The creepage distance of the insulators shall not
be less than 80 mm.
The insulators used in the LT/AC system shall have the following minimum flashover
value and mechanical strength :
Dry flashover voltage : 25 kV
Wet flashover voltage : 12 kV
Ultimate mechanical strength : 1000 kg.
The trolley line holders shall generally conform to the design shown in the drawing to
be furnished to the successful Tenderer. All sharp edges shall be ground smooth. The
porcelain insulators shall be manufactured and tested as per IS: 1445 1997

04. Supporting brackets

The trolley line conductors shall be mounted on holders. The holders shall be bolted on to
brackets which in turn shall be welded on to crane girder at stiffeners at regular intervals. In
normal run, intermediate type of brackets shall be used, but when sectionalizing gaps or
expansion joints are provided, sectionalizing type of brackets shall be provided.

05. Steel to Aluminium straps

These are meant for connecting parallel aluminium bus, at expansion joints, power supply
cables from load break switch. They shall be complete with MS cadmium coated bolt nuts,
spring washers, lugs etc.

06. Signal lamp assembly

Signal lamp assembly shall be industrial, heavy duty dust tight and water proof in
construction suitable for indoor or outdoor locations. The units shall comprise three lamps
for three phase with red glass lens and reflectors. The lamp shall be provided with dropper
resistance connected in series with the lamp and the resistance shall be rated for
continuous inclusion in the circuit. Alternatively, a built-in transformer may be provided to
suit the lamp voltage.

07. Aluminium parallel bus

These buses shall be of E.C. grade aluminium. They shall be free from any deformity in
profiles.

08 Current Collectors

2 nos. current collector shall be provided per trolley line each rated for 100% of total rating
. The collector shoe will be of heavy duty design and chamfered at both ends, each rated

BHILAI STEEL PLANT


for 100% of total crane rating. Double collectors on each earth trolley line shall be provided
and these shall be different from those on power trolley line. Collector shall be multi hinged
for self aligning. Collector will be designed in such a way that load is transmitted not no
the insulators but on the insulator stud to avoid damage to insulators.

09. Power distribution on crane

One adequately rated isolator (MCCB/ACB) with locking facility shall be provided
immediately after current collectors on incoming line on the crane. The isolator shall be
capable of carrying current of two largest motors.

Power from the isolator shall be taken to the air circuit breaker to be provided in operators
cabin. In case of pendant operated cranes, this circuit breaker shall be located in protective
panel located at bridge platform.

The breaker shall be provided with under voltage, over load and short circuit releases. The
breaker shall also be with earth fault protection . The breaker can be closed only when :

- All master controller handles are in neutral position.
- None of the stator or directional contactors are in closed positions.
- Emergency corner switches not operated.
- Door/Gate switch are not actuated and gravity limit switch for hoist motion not
operated. Power for lighting and magnet circuits shall be tapped from the incoming
side of isolators near current collectors.

10. Power supply for CT. motion

Flexible trailing cable systems mounted on retracting support system shall be used. The
system shall consist of insulated multi-conductor or several single conductor cable with
permanent termination on the bridge and on the trolley. The flexible trailing cables shall
have ample length and shall be supported by means of properly designed movable clamps.
These clamps shall be fitted with rollers and shall run freely on a guide rail allowing relative
movement of bridge and trolley without undue stress or wear on the suspended cable.
Provision later stage in case of necessity. The flexible cable shall be butyl rubber or EPR
insulated CSP sheathed type.

For rotating trolley cranes, power supply shall be through festoon cable arrangement
slipring or cable basket. Cable reeling drum or cable basket shall be used for power supply
to the magnet from the trolley. Two spare turns of cable provided on cable reeling drum.
The cable reeling drum shall be directly driven by hoist mechanism, a clutch shall also be
provided to disconnect the drum from hoist mechanism.

Flexible cables system mounted on latest PVC linked chain system in normal area &
metallic chain systems in hot area. (New point)

11. Meters

Ammeter and voltmeter with selector switches shall be provided on the incoming line in
operators cabin.

Ammeter and voltmeter shall be provided on DC side for Electromagnets.

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12. Control features

All controls shall be fully magnetic, operated through master controllers. All travel motions
shall be provided with plain rotor resistance control with plugging. For long travel drives, the
electrical control shall be grouped for the individual pair of motors separately in case of four
motor drive and each pair of motors shall be able to drive the crane at reduced
acceleration and speed. As an anti-skewing measure, out of a pair of motors for LT., if one
drive motor trips, the other drive motor shall also be switched off. For pendant control,
plugging shall be avoided for travel motion.

Brakes shall not be used for speed control.

Synchronization of separate drives where required shall be done with the used of solid
state thyristor control.

For all hoist motions, except where creep speed is required, plain rotor resistance control
shall be provided on all master controller notches in the hoisting direction. The rotor
resistance shall be cut out gradually when moving from lower to higher notches such that
current peak of 2 times the rated current is not exceeded. In the lowering direction of the
motion, controlled lowering shall be provided using one/ two plugging notches, one single
phasing notch and one/ two super synchronous power lowering notches. For obtaining
creep speed, conventional methods like planetary gear system, DC. injection (where
requirement calls for creep speed in lowering direction only) etc. may be offered.

Hoist control circuit shall also be provided with anti-drop feature i.e., whenever the master
controller is brought back to zero position from higher notches in both directions, the motor
shall automatically be connected to hoisting direction for some time (time adjustable
through timers) to avoid the downward drift of the load. Brakes shall be clamped in zero
position of the master controller.

13. External control of auxiliary hoist and CT of LRS Crane

Tenderer shall supply one no. of Ground Control Post in Pedestal for installation in PCM
control room. The control post shall have following facilities:

a) Control on PB- This shall transfer the control of CT and auxiliary hoist from cabin ,
master controller to ground control post and will not allow LT motion from cabin.
b) For CT and aux. Hoist 4 push buttons each (total 8 PBs) shall be provided on ground
control post for following application:
c) 10% speed of hoist & lower
d) 30% speed of hoist & lower
e) 10% speed of CT forward & reverse
f) 30% speed of CT forward & reverse

The control post shall be connected to the main control of cabin on crane through hear
resistance flexible cable with copper conductor arrangement and plug and socket system.
The socket shall be fixed to the cabin. The no. of pins for socket, no. of additional aux.
Contactor, no. of cores for flexible cable to achieve the above control shall be decided by
the Tenderer during detail engineering and shall be included in the scope of supply of
Tenderer.

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Further, Tenderer shall quote radio control system to achieve the above control
requirement as an optional feature. Cost for the radio control option shall be indicated
separately.

14. Thyristor control drives

Thyristor control shall be provided for all the cranes operating in areas where ambient
temperature is more than 50 deg. C . Control shall be achieved through master controllers
for each direction. Rated and creep speeds are to be provided in each direction i.e.,
hoisting and lowering. Creep speed shall be 10% or lower as per operational requirements
of rated speed.

The thyristor regulator shall be fully controlled and suitable for four quadrant operation.

Speed control of the slipring motor shall be achieved through regulation of stator voltage
with resistance in the rotor circuit, if necessary. The reversal of direction shall be through
magnetic contactors which shall open and close at zero current.

The continuous rating of the thyristor converter shall be at least 2.0 times the motor rated
current at the mechanical KW and the converter shall be designed and rated for load
requirement taking care of peak currents during acceleration, normal operation and
regeneration conditions. The dv/dt and di/dt rating of the thyristors shall be suitably
selected.

The repetitive PIV rating of semi conductor devices shall not be less than 2.5 times the
peak of normal system voltage. Thyristor bridges shall include R.C. snubber circuits across
the thyristor, high speed semi-conductor fuses with micro-switches for monitoring of failure.
Closed loop regulation suitable for the system with various feed back such as speed,
current etc. shall be provided. Speed feed back shall be through tacho-generator of
permanent magnet type mounted on the non-driving end of the motor shaft. The regulation
shall include ramp generators, potentiometers for various setting, various regulators, signal
conditioners, logic command module sequence, module, trigger module, zero and over
speed monitor, torque less protection module etc. as per the requirements. The control and
regulation equipment shall be able to maintain their rated performance and control quality
even under conditions of variation of +10% and - 15% in voltage and +5% in frequency. A
zero current sensing device shall be incorporated. The reversing of stator contactor shall
be done at zero current. Braking down to zero speed shall be electrical with mechanical
brake setting only at zero speed. Protective features like anti-drop etc. shall be
incorporated to prevent load setting. The circuitry shall also provide for the protection
against failure of motor torque such that the mechanical brake sets in such cases. All other
features of conventional crane controls shall also be built into the scheme. The following
shall also be provided on the A.C. side.

- Surge suppressor
- Over current protection
- Overload protection
- Single phase protection
- Phase sequence protection
- Ammeter and voltmeter with selector switches
- Isolating switches

Control and auxiliary supply shall be provided with separate transformer and under voltage
protection.

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The test shall be performed as per IEC : 146.

Details of the system offered shall be furnished along with necessary single line diagrams
and block diagrams.

All the control modules shall be grouped in a sheet steel enclosure. The control module
cards shall be made of epoxy glaze and suitable for plugging into the racks. The cards shall
be locked into the rack, which carries a sealing bar and assists locking of the cards thereby
cutting down on the wear of the printed circuit connector contacts which can be subjected
to high rate or vibration and further avoid the disconnection of cards from the connector.
The thyristor panel shall be suitably mounted so that little vibrations are reflected to the
components and connection.

The cables for the thyristor controller and associated equipment shall be laid and clamped
separately on the crane.

15. VFD control drives

VFD control shall be provided for cranes operating in areas where operating temperature is
50 deg. C . Control shall be achieved through master controllers for each direction. Rated
and creep speeds are to be provided in each direction i.e., hoisting and lowering. Creep
speed shall be 10% or lower as per operational requirements of rated speed.

The VFD shall be fully controlled and suitable for four quadrant operation (active front end
type) . Other details of VFD shall be as per respective clause for VFD in the GTS.

16. Panels

There will be separate panels for each motion in addition to the protective panels and
resistance panels.

All panels shall be of free-standing floor-mounting construction, suitable to withstand
vibrations encountered on crane. Hinged doors shall be provided for closed type panels.
Panels shall be front wired. Front wired live points of bottom most equipment shall be
mounted at least 350 mm above the bottom cover of the panel. Panel shall be fabricated
from 2.0 mm thick steel sheet.

Power and control terminals shall be segregated. 10% spare terminals shall be provided in
each panel.

Equipment in the panel shall be so mounted that their removal or replacement from the
front is easy.

Separate control panel for each motion shall be provided.

Panels shall be of closed type when mounted on bridge platform.

The panels shall be mounted along the girder facing the hand railing. Sufficient clearances
shall be provided between the panels. A minimum clearance shall be provided in front of
the panels for walkway and approach as per I.E. Rules. The panels shall be supported in
the back from the girder to avoid vibrations. Open type panels may be used for installation

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inside the box girders. In this case, adequate lighting and ventilation shall be provided for
the room.

17. Switchgears

Each mechanism motor shall be provided with MCCB, contactors on stator and rotor sides,
Electronic over load relays and suitably rated rotor resistances. In case of thyristor
controlled drive, each mechanism motor shall be provided with breaker / switches,
transformer, thyristor, rotor resistances, contactors on stator and rotor side etc. Each motor
shall be fitted with a tacho-generator for speed feed back. The speed range shall be 0-
160% of rated speed.

MCB shall be provided in the control circuit of each motion.

Each brake circuit shall be provided with a suitable contactor.

Rating of contactor selected for any mechanism shall be at least 50% higher than the
respective motor full load current for the mechanism at 40% duty cycle. The minimum
rating of the contactor used shall be 32A and the life of each contactor shall not be less
than 10,000 hrs. of operation.

Reversible directional contactors shall be inter locked both mechanically and electrically.

18. Motors

Heavy duty reversible crane service, totally enclosed fan cooled, foot mounted, wound rotor
motor conforming to latest edition of IS:325-1996 shall be used for various drives. Class of
insulation shall be F/F (Stator/Rotor) with temperature rise limited to that for B Pullout
torque to the not less than 225% and 275% of full load torque corresponding to 40% CDF
for class 1 & 2 and class 3 & 4 duty cranes respectively.

The main motor shall have following speed ranges :

a) Class M3 & M5 duty cranes :

Main & auxiliary hoist : 750 rpm
Long & cross travel : 1000 rpm

b) Class M7 & M8 duty cranes :

Main & auxiliary hoist : 600 rpm
Long & cross travel : 750 - 1000 rpm

All motors shall have the terminal box at top. Frame sizes shall conform to IEC Standards.

Horizontal foot mounted and with tapered shaft extension.

While selecting the motor rating following shall also be taken into consideration :

- Duty type S4 & S5
- Cyclic duty factor
- Number of switchings per hours

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- Type of controls used
- Inertia of the motor and mechanism
- Ambient correction factor
- Service factor
- Derating for thyristor control
- Wind pressure
]
Maximum permissible operating speed shall be 250% of synchronous speed or 2000 rpm
whichever is less. Over load capacity 150% of full load current for 2 minutes without damage or
permanent deformation.

19. Brakes

Brakes shall be D.C. electromagnetic type , confirming to AISE standard. The brake coils shall
be made of copper and of insulation class F.

Brakes shall be designed to fail safe whenever the current is interrupted either intentionally or
by failure of the main supply.

Brake circuit forcing shall be provided for D.C. brakes. D.C brake circuit shall be switched off
on D.C. circuit for quick operation of brake.

A separate set of parking brake for L.T. motion shall be provided for each out door crane.
Power supply for these brakes shall be obtained from protective panel.

20. Limit switches

Roller lever operated, resetting limit switches shall be provided for all travel motions. For each
hoist motion, a rotary cam type over hoist and over lower, self resetting limit switch shall be
provided. This limit switch shall have independently adjustable cams for hoisting and lowering
motion. The cams shall have adjustability such that end limit can be set to within 100 mm of the
hoisting or lowering motion. In addition to this, a back up ultimate limit switch of series/ shunt
gravity type shall be provided to prevent over hoist. The later shall be of manual reset type. In
case of cranes handling hot metal, the gravity limit switch shall preferably be of series type.
Provision shall be made to bridge the gravity type limit switch contact by push button/ switch or
any other means to lower the load. An indication shall be provided to the operator whenever
this limit switch has operated. Suitable limit switch shall be provided for slack rope, gate/door
opening, slew mechanism, grab closing/ opening etc. wherever necessary. Protection class of
the limit switch shall be minimum IP 65 .

21. Anti- Collision Devices

In cranes where two or more cranes are operating in the same bay( at same or different level )
all cranes shall be provided with suitable Anti- collision system. Anti-collision device shall be
electronic type.

A sound signal shall be provided to the crane operator when they are at certain safe distance
apart ( distance to be adjusted as a function of speed at site) and crane shall stop. After few
seconds, it shall be possible to run the cranes towards each other ( or only one crane can move
towards the other) till buffers of the cranes meet by providing by pass in the operators cabin.

Anti-collision shall also be provided on trolley for twin trolley cranes along with suitable by pass
arrangement.

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22. Resistances

Air cooled, robust, heavy duty, corrosion resistant fechral edge wound resistance. Resistance
shall be in single phase execution. In a particular box the rating of resistances shall be the
same. Resistance shall have vibration proof only.

Rated for 10 minutes duty. Continuous duty rating of resistances shall be provided in case of
hoist motions controlled by thyristor converters.

Maximum temperature (absolute temperature) of resistor elements shall be limited to 335 deg
C at desired duty. Suitable tapping points shall be provided.

Resistance boxes shall be mounted in racks that permit independent removal of any selected
box.

23. Master controller

Cam type master controller with joy stick type lever shall be used.

Separate master controllers for hoist ,LT & CT shall be provided.

Duel master controller operated with single handle shall not be used.

Master controller for each motion controls shall have four/ five notches in each direction.
Master controller for electro- shall have three positions i.e Lift- Off-Drop. It shall have spring
return from drop position to Off position.

24. Lighting, socket outlets, bells etc.

Lighting shall be provided in operators cabin, stair cases, platforms and working areas.

Minimum 4 nos. 400 watts high pressure sodium vapour flood lights equally spaced (under
crane girders) about the crane span shall be provided along with shock absorbing and anti-
swing suspension arrangements. More numbers of fittings shall be provided if required for
cranes with longer span and/or longer height of lift.

Fluorescent lamps with necessary fittings shall be used for operators cabin, staircases,
platforms etc.

Adequate number of hand lamp socket outlets ( 2 Pin, 10A, 24V) and power socket outlets ( 3
Pin, 20A, 240V) shall be provided along with switches socket & switch shall be interlocked
suitably. A hand lamp( 160W SLS lamp with enclosed type battery and wire guard) along with
sufficient length (15m) of cable with a plug shall also be provided for each crane.

An alarm bell shall be provided on each crane.

25. Electromagnets

All magnets shall be suitable for steel plant application and shall be welded construction.

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Magnets shall be rated for 230 V DC and suitable transformer rectifier units shall be provided
for feeding them. Rectifiers shall also be suitable protected by suitable protective device.

Magnets shall be class H insulated, at least 50% rated, copper conductor would and shall
have surge suppressor box and separate in terminal box for termination of cable. Magnets for
production cranes handling hot products shall be 75% rated. Surge suppressor shall be
compact , non-linear resistor silicon carbide thyrector, variator or metrosil type.

Each magnet shall be provided with suitable plug socket unit.

One earth terminal on magnet to be connected to spare core in magnet cable.

Wherever specified, a set of batteries, a battery charger, one annunciation system and other
accessories shall also be provided along with magnet so that the magnet can hold the full load
for atleast half an hour in case of power failure.

25. Equipment in operators cabin or on pendant unit

a) In case of pendant controlled crane following shall be included on the pendant unit :

Push button for : Hoist slow, hoist fast, lower slow, lower fast, left cross
traverse, right cross traverse, forward long travel,
backward long travel, emergency stop conditions.

Switch for : Lights and bells

Lamps for : Power ON indication and emergency corner switch
operation.

b) In case of cabin operated cranes :

The operators cabin shall contain the following :

- Master controllers for all the motions and magnet (wherever applicable).
- Emergency stop push button.
- Foot switch for alarm or bell.
- Switches for all lighting equipment on crane.
- Switches for air conditioner, exhaust fan and for cabin fan.
- A fire extinguisher.
- Insulating mat and operators chair.
- Cabin light.

Annunciation panel with indication lamps for power ON control ON emergency corner
switch operated, ammeter and voltmeter with selector switches.

c) In case of master controller operated cranes :-

In this case there should be the facility of controlling the crane from the control pulpit .

All the control facility available in case of operating from the operator's cabin is duplicated
in the control pulpit through the cable .

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d) Radio remote control :-

In this mode of control system, all the 3 motions
Hoist .
Cross travel.
Long travel.
can be controlled .

The system shall have capability to provide range of 1.5 times the long travel distance of
the crane .

In the case of signal failure, all motion shall come to a safe stop.

The system shall have facility of controlling speed in two steps :-

(i) Slow speed on the first step of the breaker contact / pushbutton of the radio remote
control representing the first or second notch of the master controller.

(ii) Full speed on the second step of the breaker contact / pushbutton of the radio
remote control representing the final notch of the master controller.

Transmitter :-

Transmitter shall have following features :-
- Constructed with sophisticated microprocessor technology and surface mounted
electronics .
- Transmission type :- FM FSK
- Transmission speed :- 9.6 Kbps .
- Built in self test for all functions .
- Transmitter shall consist of switching breaker , dial switch and push buttons .
- Switching breaker shall be non locking to zero position or maintained function .
- Indications :-
Operation status
Battery status
Indicators that display information from crane .
- PIN -code (Personal Identification Number)
- Internal antenna .
- Rechargeable battery .
- Battery 7.2 V NiCd
- Operating time :- About 8 hours .
- Different operating frequencies (minimum 16 nos.)
- Two hand upstart.
- Stop push button .
- Operating conditions :- Areas having large temperature variations , dusty , more
vibrations , oil and humidity .
- Operating temperature range :- Min. 10 deg.C to Max. 60 deg.C
- Protection class : IP - 54.
- Casing material : Polycarbonate / ABS plastic .

Receiver :-

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Receiver shall have following features :-
- Upto 20 functions exclusive safety relays (for transmitting preset reference values to
VFD in the crane).
- 2 safety relays (for control of main contactor)
- Power supply suitable for 240 V AC ,6 A.
- Minimum 16 different operating frequencies.
- Two redundant microprocessors for monitoring each others .
- Cyclically redundancy check check for high secutity of transmitted radio messages .
- Frequency scanning in the receiver .
- Memories last 10 users .
- Interlocking of the relays .
- Momentary or latched relay functions .
- Two hand up start ( to avoid unintentional start).
- Protection class : IP - 65.
- Casing material : Aluminium profile for fast mounting on DIN rail .
- Operating temperature range :- Min. 10 deg.C to Max. 60 deg.C

26. Enclosure Class

a) For indoor operations
- Resistance boxes : IP : 11
- Motors : IP : 55
- All other electric equipment : IP : 54

b) For outdoor operations
- Resistance boxes : IP : 33 with canopy
- Motors & panel : IP : 55 with canopy
- All other electrical equipment : IP : 65 with canopy

27. Cables

Power cable suitable for 3 Phase, 4 wire, AC power supply system.

All cables shall have stranded copper conductors. Control wiring shall be with 2.5 mm2
copper; minimum size of power cable shall be 6.0 mm2. Fixed wiring on cranes shall be
carried out with PVC insulated. PVC sheathed armoured cable or EPR insulated CSP
sheathed cable or better.

All flexible cables (i.e. cables for magnet, trolley, feed, pendant unit etc.) shall have copper
conductor, EPR insulation and CSP sheathing or better.

All cable shall be suitably de-rated for grouping and higher ambient temperature.

All cables shall be of 1100 Volts grade.

All accessories like cable glands, clamps, pipes, wire and terminal marks etc. shall also be
provided.

Cable laying and terminations shall be such that the chances of cables getting damaged is
remote.

Cable sizes shall be selected considering motor rated current.

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In all passages and on trolley the cable shall be laid in trays and shall be covered by similar
trays and properly clamped & fixed.

01 LT Power Cable

1.1 kV, heavy duty power cable, 4/3.5 core with stranded sector shaped (sm) or with
compact circular stranded (rm/V) or circular stranded (rm) Copper conductors as
applicable, PVC insulated suitable for 70C operation as per IS:5831-1984, core stranded
together provided with a common covering of PVC inner sheath, galvanized round steel
wire armoured and PVC outer sheathed, multi core conforming to IS:1554 (Part-I 1988)
Type TWY.

02 Control Cables

1.1 kV, circular stranded (rm), annealed copper conductor, PVC insulated suitable for 70C
operation, as per IS:5831-1984, cores stranded together provided with a common covering
of PVC inner sheath, galvanised round steel wire armoured and PVC outer sheathed, multi-
core similar to IS:1554- (Part-I)-1988, Type YWY.

03 Flexible Trailing Cable

1.1 kV grade, heavy duty type with tinned annealed high conductivity flexible copper
conductors, ethylene propylene (EPR) insulated and chlorosulphorated polyethylene (CSP)
sheathed conforming to IS:8130-1984, IS:6380-1984 and IS:9968 (Part-I)-1988.

28. Earthing

A ring earthing system shall be provided on the crane. Each and every electrical equipment
shall be connected to this earthing at least at two points. However the electronic circuit
insulated earth wire shall run in panel and terminate at main earth connection only at one
point. The earthing shall be connected to the fourth trolley line in DSL system through 2 nos
of current collector. Additionally current collectors shall also be provided on crane rails for
earthing on crane . All these collectors shall be connected to earthing ring.

An earth core shall be provided in trolley feed cable and the magnet. The cable reeling
drum shall have a separate slipring for earthing purpose.

It shall conform to general specification for earthing.

Rubber mattings shall be provided in front of the protective and control panels.

All bonds between earth conductors and crane parts shall be welded if possible, or rivetted
and soldered. Where screwed bonds are made, care shall be taken that there is
satisfactory contact surface and nuts shall be locked to prevent their loosening. Earth
connections to equipment shall be made by means of multi strand flexible conductor to
adequate section.

The earth ring on the crane/ machine shall be connected to the plant earthing system
through to gantry rails. Each end of each gantry rail shall be bonded to the plant earthing
system.

In addition, intermediate earthing bond shall also be provided on the rails at every 60 m in
case of longer tracks.

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lbU o 2U5
Flexible copper bonds shall be provided across any gap in the running gantry rail.

For mobile equipment with flexible cables, one separate copper conductor of adequate size
shall be provided for earthing.

29. Crane weighing system :

Electronic weighing system including calibration equipments, cables, load cells and panel
mounted associated electronics (microprocessor based) with communication capability with
PLC on bus.
Cranes & hoist (as per scope of supply) including their complete electrics & control (as
given in relevant chapter) including power supply, power conductor lines (DSL) , Load
break isolators (to be located in bay) & cables .

Crane weighing system to be connected to ground station by Radio link module. Necessary
hardware & software including cables for above as well as communication of ground station
with main automation network of shop automation system to be considered.

Other details of crane weighing system :

1. The Weighing system shall be designed, manufactured, assembled & tested in
accordance with relevant OIML / NTEP standards.
2. Load cell shall be of globally reputed make, confirming to OIML/NTEP Standard &
preferably digital type. Load cell shall be easily replaceable type, provided with safely
devices from impact load, vibration, heat & dust.
3. Weighing system shall be auto zero & auto calibration facilities.
4. Redundant electronics shall be provided.
5. Test weight for calibration shall be provided.
6. Two nos. large display unit shall be provided.
7. The requirement of the system are:
i) The Weighing system will be sufficient to measure, display and telemeter the loading
material weight, meet all operating requirement and necessary safety provision
including alarms for abnormal conditions. Design should support better tolerances in
the mechanical system.
ii) The equipment selected for the purpose will be suitable for a continuous and reliable
functioning in environment generally prevailing in steel plant area. Signal transmission
will be through radio communication. The frequency used shall be in license free bands
as per prevailing standards in India.
iii) The designed will include all necessary precautions and provision for the safety of
operating and maintenance personnel and equipment.
iv) Accuracy of the system will not be less than 0.5% of FSD.
v) The Crane Weigh unit will be able o tolerate sudden shock loads caused by the lifting
and traveling of crane,. Weigh unit will be suitable for continuous loading for long
durations. Electronics will be resistant to vibration prevalent in cranes.
vi) Weight signal shall not be affected by the height at which load is weighed.
vii) The Weighing system shall have protection against strong magnetic field, electrical
surge, RF interference and heat & dust.
viii) Data updation on real time basis in the central computer.
8. The scope of work includes Supply, Erection, Testing and commissioning of Crane
Weighing systems as per following:
i) Crane Weighing units complete with top & bottom crane mounting accessories,
weighing electronics, wireless communication interface, anti heat shielding for the
equipment, protection against EMI, batteries and chargers, one standby battery for

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2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc lbl o 2U5
each weigh unit, power supply unit etc. the Amp. Hour of the battery shall be adequate
enough for minimum one month working.
ii) Hand held unit based on radio frequency signal with toggling facility for current and
cumulative weight display complete and charger, long range antenna ( as per site
requirement ), wireless communication interface, provision for entering product and
customer details. This unit will have calibration facility with password protection.
iii) Wireless Transreceiver at PC end (with IP65 enclosure), power cable, antenna (if
required as per site condition)
iv) Commercial grade PCs.
v) The required tools and testing instruments for normal maintenance and operation of
the equipment.
vi) The weighing system shall have real time connectivity to the plant MES / ERP through
plant wide network.
vii) Supply of following tools and testing equipments:
a) Digital Multimeter 4 digit- 2 nos. (make: Philips / HP / Fluke)
b) Portable Think pad based software programmer (make: HP / IBM / SONY) - 1 no.
c) Universal calibrator (make: HP / Fluke)-1 no.
d) Professional tool kit (make: RS / Philips)
viii) Integration of subunits.
ix) Supply of complete data, design calculations, technical literature and documents,
erection / maintenance and operation manuals, erection drawings, Quality Assurance
Plan (QAP) and as built drawings.
x) Supply of special tools and tackles, commissioning spares.
xi) Component level training to maintenance staff of BSP at the tenders works.
xii) Earthing.
xiii) Stamping and verification at the manufacturers works by the tender as required under
Weights and Measures Act.
xiv) Suitable safety devices for the protection of the weighing and processing system
against impact loading.

1.02.21 Erection Specification

1.02.21.01 Guidelines for design of system and engineering the layout of electrical
equipment.

001 General
The tenderer shall prepare the layout drawings for civil assignment and civil drawings for
construction of the substation buildings and civil buildings for other electrical premises
taking into consideration the requirement listed below. In case of total turnkey contract
the civil aspects mentioned in following specification shall be adhered to while planning /
executing civil work.

002 Electrical premises

All electrical premises shall have adequate space to accommodate the electrical
equipment from the point of view of operation and maintenance, and conform to IE
Rules & Regulations.

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The clearance between the ceiling of the electrical room and top of the tallest
equipment shall not be less than 1m, 2m where the equipment are to be
maintained from top and additional height of lifting tackle wherever required.
Lifting/handling facilities shall be provided. Rolling shutters shall be provided to
facilitate transportation of the equipment into and out of the electrical room, MCC
rooms.
Electrical room located on the top floors shall have erection openings and landings.
All electrical rooms shall have cable basement/cable galleries /cable trenches as
per equipment layout in the electrical rooms . The clear height of the
basement/cable gallery walkways shall be minimum of 2.2 m for cable tunnels and
3 m for basement/galleries.
The wall of the basement shall have water proofing and draining facilities below
ground level.
All electrical rooms shall be constructed with heatproof material at the roof if it is
exposed to sunlight .
Cable basement/galleries shall be provided with suitable lighting/ventilation
facilities.
24V AC sockets fed from dry type L.V. transformers shall be provided for hand
lamp connection throughout the premises including basement and cable tunnels.
Airtight double door arrangement shall be provided for electrical rooms and
basement. The stairs to the basement shall be from inside the electrical room.
Welding power socket outlets shall be provided within basement at intervals of
60m with minimum of one, where basement is less than 60m long.
Electrical room and cable galleries/basement shall be considered fire hazardous.
Roofs of the electrical premises shall be fully watertight and moisture proof.
Erection openings with removable cover plates shall be provided on the floor of the
electrical rooms connecting the basement/cable gallery.

003 Control rooms/pulpits

Location of control posts shall be decided taking care of clear visibility.
All control rooms shall be air-conditioned and temperature shall be 24 deg. C.
Air lock rooms shall be provided for all the control room / pulpits .
Inner walls shall be sound proof.
Granite flooring shall be provided.
Window glass shall be toughened, heat resistant and of greenish tint, hinged glass
to be opened from inside.
Double glass panels, wherever required, shall be provided to make the control post
heatproof.
Suitable wire mesh shall be provided for the glass windows for protection against
mechanical damage wherever required.

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004 Cable tunnels

Standard cable tunnel size:
Full tunnel : 2200 mm (W) x 2200 mm ( clear height)
Half tunnel : 1500 mm (W) x 2200 mm (clear height)
Partition door between basement and the cable tunnel shall be air tight and of fire
retardant material. Cable tunnel shall be provided with fire / smoke detectors as per
norms.
Gradient of the floor at transition from one elevation to another shall not exceed 15
deg. Gradient shall be in the form of ramp.
Floor gradient towards the water collecting pit shall not be less than 0.3%.
Plate inserts (200 x 100 x 6 mm) at an interval of 1500 mm shall be provided on
the wall along the length of the tunnel. Three rows of inserts shall be provided at
suitable intervals along the height.
Plate inserts shall be provided at an interval of 1.5 m under the ceiling for lighting
fixture.
Entries to the cable tunnel shall be provided generally at 70 m interval along the
length of the tunnel inside the shop or at least 2 entries in case of small tunnels .
Tunnel walls shall be waterproof design.
For interplant cable tunnels, long tunnel shall be split into compartment not
exceeding 150 m with fire proof partition doors.
All cable tunnels shall be properly ventilated.
Atleast two evacuation exits should be provided in each of the cable gallery and
cable tunnel. The distance between any point and exit should not be more than
35m. The distance from dead end of cable gallery/cable tunnel to the exit should
not be more than 25m.
All the cable tunnels and cable galleries shall be provided with sump pumps for
pumping out seepage water. Sump pumps shall be provided with high level/low
level switches for automatic operation.

005 Cable shafts

Cable shafts shall be of either civil or structural design as per requirement.
Landing platform shall be provided at every 5 m of height.
Suitable cat ladders shall be provided in the cable shaft.
Suitable ventilation/lighting facilities shall be provided for the cable shafts.

006 Clearances inside the electrical rooms

Sl.No. Clearance Min. Distance

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(in mm)
1.0 Back clearance 1250
2.0 Front to front clearance between drawout / semi-
drawout panel boards
2500
3.0 Between two panel boards installed in a row 1000
4.0 Between front of the panel to the wall of the room 2000
5.0 Between the wall and end of the switchgear / MCC 1000
6.0 Back to back clearance 1500
7.0 Back to front clearance 2000
8.0 Between the bottom of the ventilation duct and top of
the electrical equipment
As per statuory
requirement and
regulation

Resistance boxes shall be floor mounted and shall be placed on the floor near the
respective MCC.
Disposition of control desk, mimic boards, instrumentation panels shall be properly
located for visibility and operational convenience.
Profile & dimension and painting of control desk / mimic panels shall be same as
for control room for aesthetic design
In any other case, the layout shall confirm to provide clearances as per Indian
Elect. Rules.

007 Transformer rooms

All mineral oil filled transformers shall have oil soak pit around it. These soak pits in
turn shall be connected to a common catch pit for collection of oil. The capacity of
catch pit shall be equal to 1.2 times of the oil content of the biggest transformer.

In case oil filled transformers are located inside the shop, the catch pit shall be outside
the shop connected to soak pits by pipes. Also the transformer room shall
be enclosed on three sides. Access side may have steel framed gate with expanded
metal jali doors with wicket door provision.

All mineral oil filled transformer shall be separated from switchgear/electrical rooms
with partition wall. All transformers and heavy equipment shall have adequate
transportation and lifting facilities.

There shall be minimum 1m clearance all around the transformer. The ceiling height of
the rooms shall be 1.5 m above the conservator. The minimum dimension of
transformer room shall be 6mx6mx5.0m(H).

1.02.21.02 Guide-line for erection of Electrical equipment and accessories

001 General

All the electrical equipment shall be installed with proper care and as per layout
drawings. Minor modifications required at site shall be made by the contractor with

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approval of purchaser representative/Consultant for installation of the equipment. Care
shall be taken for proper handling of equipment and undue vibrations shall be avoided
particularly in case of sensitive (instrument mounted on panels) equipment.

The contractor shall have valid electrical contractor's license valid for State Govt. and
as well supervisory licence. He shall have in his employment sufficient number of
electricians and supervisors holding valid licenses for HV and LV installations. It will be
the responsibility of the Contractor to get the installation cleared and relevant drgs.
Certified / approved by Electrical Inspectors , Factory inspectors, Insurance agencies
and other statutory authorities. The Govt. fees and necessary commercial aspects will
be taken care by the Contractor.

002 Rotating machines

The erection work of motors shall include checking of all motors before installation
including thorough cleaning and checking of bearings, replacement / rectification of
defective items, greasing of bearing, if required, making minor modifications in its
mounting arrangement, wherever required, assembling and its mounting on the motor
base plate or on mechanical equipment, as the case may be, including levelling and
alignment, checking insulation resistance and improving the same, if necessary,
checking of internal connections etc.

All work associated with revisioning of motor shall also be included such as uncoupling
and removing of motor from mechanical equipment, disassembling, cleaning, checking
of insulation resistance and improving the same, if necessary, regreasing and replacing
defective items/bearings on foundation, wherever required, reassembling, placing,
levelling, aligning and fixing of coupling of the revisioned motor with mechanical
equipment.

The contractor shall check different parts and assemble the motor at site in correct
sequence wherever the motors are delivered in a dismantled state i.e. base frame,
bearing pedestals, armature, field frame etc. in separate packages.
Erection, alignment and securing shall be done under expert technical supervision.
Straight edges, feeler gauges, dial gauges etc shall be used for aligning purpose.
The height of the shaft of the motors shall correspond to the machine to be driven, if
discrepancies are encountered these shall be compensated by inserting machined
metal sim plates under the supports of the motor.
The motors mounted on the movable base frames / base plates shall be connected via
intermediate terminal boxes with flexible cables.
After the complete installation of the motors, all bolts and bolted joints of the
mechanical and electrical equipment shall be checked to ensure that they are done up

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tightly by torque wrench. A further check shall be made to ensure that the armature
can be easily rotated.

The insulation resistances of the coils and connecting leads within the machine shall be
checked against earth by a suitable megger. Insulation resistance if found less, the
machine shall be dried to achieve the desired value.
Space heaters of main drive motor required to be installed in motor foundation pits
shall be suitably and firmly mounted.
For handling the machine with the crane, the slings, lifting cables etc. shall not be
secured around the shaft. However, the armature of disassembled machines may be
lifted or supported by the shaft.
The machine shall be lifted or lowered without shocks or quick jerks to avoid any
damage.
Handling facilities of the motors shall be provided at places where direct crane
approach is not possible .

The system components delivered in separate packages like tank, gear pumps, filters,
pressure switches, thermometer, flow regulators, centrifuge etc. shall be assembled at
site and installed as per supplier's drawings. The supply and return pipelines along with
their supporting structures from the lubrication system to the motor bearing shall be
laid/erected by the contractor as per the relevant pipeline routing drawings. Meters and
gauges shall be fixed and wired.

003 Sheet metal enclosed panels, open control panels, control desks and boxes
The base frames of all panels, desks, posts etc., shall be welded to structures or to the
civil inserts provided on the floor/walls. Fabrication of supports/frames, wherever
required, shall be done by the contractor.

The shipping section shall be placed in position before removing the protective
covering to eliminate scratch/damage. The shipping section shall be moved by using
rollers under the shipping skids wherever lifting cranes are not available. The
contractor shall do the assembly at site as per manufacturer's general arrangement
drawings and installation instruction. While assembling a complete board comprising
several unit type cubicles, the board as a whole shall be aligned. The panels shall be
properly leveled prior to grouting the holding down bolts or welding the panels to the
inserts. All interconnection of busbars and wiring between the panels shall be done as
per manufacturer's instructions and drawings. Welding work on the panels shall only be
carried out after consultation with the purchaser. Damage to the paint due to welding
shall be rectified by the contractor.

After mechanical installation of the board is completed, loose instruments shall be
installed, wherever required, and wires shall be connected to the instrument. The

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wiring of intermediate terminal strips between two panels, wherever disconnected for
transport, shall also be connected.

Each post shall be mounted at the place of installation in such a way that the operator
has both the plant and the post before him.

The installation of control posts / boxes on mechanical equipment must be approved by
the purchaser.

In cases where the control posts / boxes are separately mounted near the equipment,
the contractor shall manufacture a structural support for the same before mounting the
control posts/box.

004 Static converters

The installation shall be carried out as per manufacturers' instructions & equipment
layout drawings.

The preservative grease from the metallic parts shall be removed by petrol and with
clean markin cloth. Grease from copper parts shall be removed with ethanol and wiped
with clean dry markin cloth.
The base frame of panels shall be welded to the civil inserts.
The panels supplied in separate shipping units shall be assembled at site as per
manufacturer's drawings / instructions. The unit installation shall be started with the
main converter. All the cabinets shall be aligned in a perfectly straight row and each of
them exactly leveled. All inter-connections shall be done as per manufacturer's
drawings/instructions.

005 Transformers and reactors
The transformer and its accessories and mountings like radiators, conservator,
thermometers, silicagel breathers, marshalling box, rollers etc., delivered at site in
separate packages, shall be assembled at site after cleaning by the contractor in
proper sequence as per manufacturer's drawings.
Jacks shall never be placed under valves or cooling tubes.
Suitable stopper shall be provided both in front as well as rear of transformer to keep
the transformer stationary in its position. For the front wheels such stoppers shall be
screwed on the rails.
The oil conservator and the pipes shall be erected as shown in the manufacturer's
drawings. All radiator tubes shall be cleaned before installation.

Before the transformer is filled/topped with oil, oil samples shall be checked by the
contractor from each container. The oil shall possess the dielectric strength as per
relevant IS/CEA. Oil shall be filled upto the mark shown.
The contractor shall also test the oil from each transformer to determine its suitability
for use. If required, the contractor shall carry out drying and filtering operations as per

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IS code of practice to ensure that moisture is completely removed and the oil is free
from impurities. This may be carried out by using oil filtering equipment to be provided
by the contractor having vacuum as well as heating arrangement. Only after the
dielectric strength of oil and other parameters are checked and approved, the external
connections shall be made to the transformers.
The dial thermometers shall be screwed to the thermometer pockets after removal of
the blind plugs.

All necessary cabling shall be connected before charging of the transformer. This will
include signaling cables upto marshalling box and from marshalling box to meters, if
not already done, as well as inter cabling between surge suppressor cubicle and
transformer secondary.
Any modifications to HT and LT terminal box to accommodate the number of cables to
be terminated shall be carried out by the contractor.
Naked light and flame shall never be used near the transformer.
Reactor shall be suitably shielded to avoid magnetic interference to electronic circuit.

006 Battery installation
All batteries shall be installed in a separate room. It shall have a water tap and
adequate ventilation facilities for acid/alkali fume extraction. Battery for UPS (SMF
type) shall be panel mounted located by the side of UPS.
Rooms having battery installation shall have acid resistant floors.
Walls will have acid resistant tiles on the side walls upto 1.5m height .

007 Busbar
Busbar installation shall be commenced from the middle section and the buses shall be
fastened without tightening the bolts. The buses shall lie freely on the insulators without
warping and if necessary, suitable packing shall be provided at the insulators.

Final tightening of the bolts shall be done after the complete laying of buses. Approved
means shall be used for tightening of the bolts.

Bimetallic strips/ washers shall be used wherever aluminium busbars or aluminium
cables are terminated on copper busbars.

008 Crane Trolley Lines

While sectionalising, one middle safety section shall be arranged slightly in excess of
the crane braking distance so that it can act as a buffer and prevent the danger of
crane collector bridging the isolator gap and leading to accidents on other section
under repair or maintenance.
Boarding or access platform shall be arranged within the limits of each repair section
for approach to the crane.

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In the middle of the run between two expansion joints and at sectionalising gaps, the
rails shall be rigidly fastened/supported.

009 Resistance boxes

The resistance boxes shall be installed on frames to be welded to civil inserts already
provided.

010 Cables Installations

Interplant cabling shall be done in cable tunnel. Overhead cable bridges / concrete
cable channels can be considered in case of lesser number of cables. Cables laid
overhead using separate structural cable bridge with suitable walkway of minimum
800mm wide for laying of cables. Cables of small in numbers and cables for drives/field
switches inside shop units shall be laid along the structures and columns of the shop /
buildings. Cables may run partly in walkable cable tunnels or underground trenches
and/or surface ducts in the shops and partly along the structures and columns of the
buildings.
In case of space constraints/restrictions, cable shall be laid in walkable cable tunnels.
Where the number of cables to be laid calls for walkable tunnels and cable shafts,
same shall be provided. Underground walkable cable tunnels shall have hydro sealing
to prevent water seepage.
For multi-layer installation, overhead cable bridge/walkable cable tunnels shall be used
depending upon the number of cables to be laid.
Laying of cables directly in underground or in trenches shall be avoided. However, it
may allowed in special case with permission from site in charge. In such case, cable
shall be laid in one layer only, more than one layer is not permissible.
Cables in trenches shall be laid on 8 cm of riddled sand and covered with 8 cm of
riddled sand. RCC slabs shall be provided for covering these trenches. The maximum
trench depth shall normally be 1.5 m and thickness of top cover of 75 mm. If the trench
is to cross railway tracks/roads or any load bearing area the cables shall be taken
through suitable GI conduits/pipes/ducts.
For crossing the road / rail track, cables shall be laid in concrete cable ducts, heavy
duty GI pipes . 25% spare conduits / pipes / duct openings shall be provided.
Installation of cables directly buried in ground shall generally conform to the
requirements given in IS: 1255 1983.

011.1 Laying in tunnels/surface ducts/on structures
Cable racks for cable trays shall be fixed at a maximum interval of 1.5 m.
Cables leaving the ground/floor shall be protected upto 2-m height by conduits/metallic
guards.

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Ladder type cable racks and trays shall be provided to lay cables in
tunnels/shafts/cable basements. Cables shall be laid in separate racks according to
the voltage / application classification. Fireproof partitions such as asbestos sheets
shall be provided between trays carrying LT & HT power cables, control and screened
cables , communication cables , instrumentation cables & telecommunication cables.
The cables shall be laid from top to bottom in order of HT on top rack followed by LT
cables and other cables on lower racks.
All communication cables shall be laid through separate conduits to be installed in
different routes with suitable separation from the other electrical cables .
Conduits carrying special cables shall be painted, coded, marked as per plant norms.
All necessary frame works and fixings for the support of cables and accessories shall
be supplied.
Cables shall be suitably protected against heat, and mechanical damages.
Cables at fire partition wall crossings shall be painted with heat resistant paint 2 m on
either side of wall.

011.2 Structures for cable laying

Power cables shall be laid on ladder type cable trays. Ladder type cable trays shall be
selected from sizes 300 mm, 450 mm & 600 mm and shall be fabricated from 50x50x6
mm MS angles for longitudinal members and 25x5 mm flats for cross members placed
at an interval of 250 mm along the length of cable tray. Control cables shall be laid on
perforated trays.
Supporting vertical racks and horizontal hooks shall be of 50x50x6 mm MS angles.
Cable racks and hooks shall be of welded construction.
To avoid damage during cable laying, cable structures shall have no scales, abrasive
or rough surfaces or cutting edges.
The over head cable bridge structure shall be designed considering future cable laying
and shall have 30% spare space for installation of future cable trays.
Walkway of minimum 800mm wide shall be provided for laying of cables.
Two numbers additional cable trays and 20% extra space on each cable tray for future
use shall be provided as far as possible .
Cable shall be fixed to racks or trays or cleats as required for proper support,
accessibility and neatness of installation. Hanging of cables racks over panels shall
not be permitted rather no cable shall be laid/pass over any electrical equipment e.g.
transformer, switchboards etc. Cable tags shall be provided at a regular interval of
30M. For cable run shorter than 30M one cable tag shall be provided in the middle.
These tags shall be in addition to end cable tags. The cable tags shall be marked with
cable number, size and voltage grade. Middle tag shall be indicated with destination.
The end tag shall be with second terminal point.

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Cables shall be clamped rigidly at an interval of not more than 1000 mm in horizontal,
and 500 mm in vertical & inclined run and at bends.

In the cable basement/cable galleries, cable structures shall be properly arranged
giving sufficient clearance for movement of personnel from one part of the
basement/gallery to the other. It shall also be possible to escape easily in case of fire.
Cable passing through water/scale pit/acid fume etc. shall be laid in PVC pipe with
PVC junction boxes and pull boxes etc Where cable racks or trays cannot be erected
or the number of cables on the route does not justify their use, cables shall be cleated
direct to walls or structural steel work.
Perforated trays shall only be used where necessary for the support of a number of
small cables. Each tray shall be firmly supported at suitable intervals and shall carry the
weight of its cables without sagging. Trays shall be painted and where the surfaces
or edges are cut or otherwise impaired during erection, they shall be made good by
coating with aluminium paint.

Small cables may be bunched together under one saddle provided that in any bunch all
cables have sheaths of the same material. The number of cables shall not exceed four
wide and two deep.

Not more than one cable shall be drawn into one conduit unless otherwise agreed.
After the cable has been drawn in, the conduit shall be sealed by an approved means.

After complete installation of racks and trays etc. it shall be painted with a primer of
red oxide(zinc chromate)and a top coat of finishing paint as approved.

Fire protection barrier as approved by purchaser shall be provided between HT cables
on racks laid on top and LT cables on racks below the HT cable rack.

All cables shall be tested for proper insulation before start of laying work.
Cables shall be laid in conduits, racks/trays, cable tunnels/trenches, along with
structures or buildings, as per cable routing drawing and cable list.

Suitable adjustment shall be made in cable routes, if required at site, with a view to
avoid any interference with any part of building, structures, equipment, utilities and
services with the approval of the purchaser.

While laying cables, care shall be taken that kinks, twists or mechanical damage do
not occur to the cable.

All bends in cables shall be made with due consideration to the minimum permissible
bending radius of the cables.

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Loops shall not be allowed to be formed during the laying of the cables. When being
pulled, the cable shall not be allowed to drag drawing along the ground or over a
second cable already laid. Special care shall be taken while pulling through an opening
where other cables have already been laid. Only approved cable pulling devices shall
be used.
No joints shall normally be made at any intermediate point in through run of cables
unless the length of the run is more than the standard drum length. In such cases
where jointing is unavoidable, the same shall be made inside proper bases having
plastic moulds and shall have moulded epoxy resin construction. Provision shall be
made for earthing continuity at the joint. Cable splicing and jointing shall be done in
accordance with the relevant IS, code of practice and manufacturer's instructions.
Insulation resistance of cables shall be checked before cable jointing.
Adequate length of cables shall be pulled inside the switch boards, control panels,
control desks, etc. so as to permit neat termination.

All cables shall be neatly dressed without interlocking or cross overs. While laying the
cable vertically, these shall be clamped at suitable intervals. Horizontal runs shall be
rigidly secured to trays on racks/hangers in all the places where the direction of the
route changes as well as at cable terminations or joints. The clamps shall not be done
up so tight that the insulation is damaged or deformed.

Cable markers shall be provided on either side of road crossing at each turning and at
30 m intervals at straight runs for underground cables.

Where cables are required to cross roads, surface drains and water, oil, gas or other
pipe lines, they shall be taken through reinforced spun concrete or steel pipes.

Entry of cables from underground to the buildings or trenches shall be through pipe
sleeves. After laying of cables, the sleeves shall be sealed with bitumen or epoxy
compound with sand matting and cement plaster to make them fully water tight.
Special consideration shall be given for protection of cables against chemical and
mechanical damage.

All cable entry openings in the equipment shall be sealed and made vermin proof. All
cable openings in walls and floors shall be sealed after laying of cables by a weak
mixture of asbestos and cement mortar.

All cables shall be provided with identification tags indicating the cable number in
accordance with cable lists. Tags shall be fixed at both ends of the cable and at 15 m
spacing for straight runs as well as on both sides wherever cables are crossing
walls/floors. The tags shall be of aluminium/PVC with numbers punched/painted on
them and securely attached to the cables by non-corrosive wires. The shape of tags

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shall be round, triangular and rectangular for control, medium voltage and high voltage
cables respectively.
Glanding shall be done for direct entry of both power and control cables into the panels
by the contractor. Compression type brass or aluminium alloy cable glands shall be
used.
The cables shall be terminated in accordance with relevant connection diagram.
Termination and clamping shall be carried out in such a manner as to avoid strain on
the terminals.

All power cable terminations shall be by means of crimping type cable lugs. For
flexible conductors, soldered termination shall be adopted. In case of aluminium power
cables termination on copper bus bars, suitable aluminium copper bimetallic washers
shall be used. Corrosion inhibiting grease shall be used for aluminium cable
terminations. All 1.5 sq.mm screened cable/ 2.5 sq.mm control cable termination shall
be made by crimping using pin / fork type (as decided during engineering stage)
insulated copper lugs. The 1.5 / 2.5 sq.mm copper lugs shall be supplied by the
contractor.

Suitable numbered and coloured letter interlocking type ferrules shall be provided for
end termination of power and control cables. Cross ferruling shall be used for control
termination as far as possible

Control cable entering switch boards, control panels, control desks etc. shall be neatly
bunched and strapped with PVC perforated straps and suitably supported to keep it in
position at the terminal blocks. All spare cores of each cable shall be segregated,
marked spare, neatly dressed and suitably tapped at both ends.
When the cores of two or more multicore cables take a common route in side
equipment, cores of each cable shall be separately bound and the separate bundles
neatly bound together.
Individual cores of control cables shall have plastic interlocked type coloured ferrules
with engraved numbers at both ends of the circuit for identification.

The contractor shall be responsible for correct phasing of motor power connections
and shall interchange connections at the motor terminals box, if necessary, during
each motor is test run.
The trays shall be earthed and rendered electrically continuous by welding the trays to
the grounding strip at not less than two places from both sides of the tray.

011.3 Cable Joint/termination accessories

The cable accessories shall include end termination kits, straight through joints and
also any special tool and tackles and accessories required for making the
joints/terminations.

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The straight through joint/termination arrangement shall be complete with all fittings
and consumables. The joint shall have electrical and mechanical withstand capability,
same as that of the associated cable. For all cables, a minimum extra length of 2
metres will be left before jointing.

The termination kit shall be of heat shrinkable type only.
The termination kits/straight through joints shall have the following features:
Electrical stress control to be provided at the cable insulation shield terminus.
An external leakage insulation to be provided between the cable conductors and
ground.
Adequate protection to be provided at the end of the cables against the entrance of
the moisture and, provision to maintain the constant pressure in the cable.

012 Exposed conduits
Exposed conduits shall be laid along walls, floors, ceilings, on steel supports etc. as
per working drawings/site requirements in consultation with the supervisory personnel.
The conduits shall be neatly run and evenly spaced.
Fixing of conduits to the supports on wall, column, structure shall not be done by
welding. Exposed conduits shall be adequately supported by racks, clamps, straps etc.
Jointing of conduits shall be done only in straight portion and not in bend portion.
The contractor shall have available at site bending facilities for conduits as well as dies
for threading conduits of diameters and threads corresponding to the standards. The
threaded ends of conduits shall be painted with anticorrosive paint. The outer ends
shall be smoothened free of burrs and sharp edges. Bushings shall be fitted at both
ends of conduits.
Flexible metallic conduits shall be used for termination of connections to motors and
other electrical equipment like pressure switches etc. which need to be disconnected at
periodic intervals.
All conduits shall be effectively connected to the earth terminal of the equipment where
it terminates.
Both ends of conduits shall be suitably earthed. Earthing continuity to be maintained by
means of flexible wire wherever two conduits are joined with sockets.
Approved conduit bending machines to be arranged by the contractor shall be used for
bending conduits at site. The radius of any conduit bend shall be as per standards for
cabling. Bends shall be free from cracks, crimps or other damage to the pipe or its
coating.

1.02.22 Earthing and lightning protection

01 Earthing

Entire system shall be earthed in accordance with the provisions of the relevant IEC
recommendations/ IS code of practice IS 3043-1987 and Indian Electricity Rules, so
that the values of the step and contact potentials in case of faults are kept within safe
permissible limits.

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Parts of all electrical equipment and machinery not intended to be alive shall have two
separate and distinct earth connections each to conform to the stipulation of the Indian
Electricity Rules and apparatus rated 240 V and below may have single earth
connections.

All shops and buildings as well as the electrical sub-stations and electrical rooms shall
be provided with a ring main earthing system each. Individual ring main earthing
systems shall again be interconnected as a network.

The ring earthing system around each building shall be laid at a distance of
approximately 1.5 m from the building and at a depth of approximately 0.8m. The ring
shall be bonded at intervals to the building steel structures, reinforcement of building
columns and also to pipes, wherever they are crossing. The earth ring shall further be
connected at intervals to deep earthing electrodes to achieve a combined earth
resistance of less than one ohm.
For the purpose of dimensioning the earthing lines/conductors, the duration of the earth
fault current shall be taken as 0.3 seconds.
For different floors in a building, localized ground mats shall be formed and connected
to the ground earthing ring through vertical risers. The earthing mat shall be common
to both power and lighting installations.

For protective earthing separate conductor shall be used for flow of earth fault current
as elaborated below.

The LV side neutrals of the Power distribution transformers shall each be connected to
two separate earthing electrodes. They shall also be connected with the neutral bus of
the corresponding switchgear and the switchgear neutral bus shall be connected to the
earthing ring at two different and distinct points. The fourth core or armour of cables
and all conduits for cables shall also be connected to the earthing mains. A continuous
earth strip shall be run in each side of cable tunnel and in cable ducts and trenches.

The power supply cables (LT) from the sub-station and the distribution cables to
individual motors shall have 4/3.5 cores.

LT power supply cables shall have four cores and the fourth core shall have cross-
sectional area of 50% of the other cores generally. The fourth core of the main supply
lines shall be connected to the solidly earthed neutral bar in the substation switchgear
as well as at the earth bars in MCC/distribution boards.
Separate electonic earthing system shall be provided for all electronic equipment like
PLC"s, weighing panel, computer etc.

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Earthing scheme to be finalized before basic engineering, in consultation with the client
and approval of OEM.

02 Conductor sizes for ground connections:

For equipment ground connections, the minimum conductor sizes used should be as
follows:
02.1 High voltage systems :-
75 x 5 mm GI flat :

Main earthing rings
Main LT switch-boards
Transformers
Earthing leads to earth electrodes.

02.2 LT system where the voltage does not exceed 650V normally :

6 Sq.mm Stranded GI wire :

Motors and starters upto and including 2.2kW, Light fitting, JBs, etc.
Instruments and miscellaneous small items protected by fuses of ratings not
exceeding 15A.

16 Sq. mm Stranded wire :

Motors and starters above 3.7 kW and upto and including 15 kW.

25 x 3 mm GI flat :

Motors and starters above 15 kW, and upto and including 45 kW

Control desks, cabinets, LCB, Welding socket outlet, Isolators, LDBs.

50 x 6 mm GI flat :

Motors and starters over 45 kW and HT motors
MCC, PDB, MLDB.
Main earthing ring for MCC room, in shop units/plant buildings
Bonds to crane gantries
Cable trays all around
LT Switchboards and other equipment protected by circuit breakers.

03 Earthing electrodes:

The earthing electrodes shall be of GI pipes 50 mm dia and about 4 mm thickness in
one piece provided with water holes and other filling devices. Earthing system for

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computers and microprocessor based equipment/ PCs shall be distinct and separate
from the power and lighting equipment earthing system.
Earthing of electrical equipment on cranes and travelling machines:
Every electrical equipment shall have double earthing.
A ring earthing system shall be provided within the crane/machine to which every
electrical equipment shall be connected at least at two places.
The earth ring on the crane/machine shall be connected to the plant earthing system
through the gantry rails. Two sets of earth collector brushes shall be provided on each
side of crane/machine to connect its earth ring to the gantry rails.
Each end of each gantry rail shall be bonded to the plant earthing system.
In addition, intermediate earthing bond shall also be provided on the rails at every 60 m
in case of longer tracks.
Flexible copper bonds shall be provided across any gap in the running gantry rails.
For mobile equipment with flexible cables, one separate copper conductor of adequate
size shall be provided for earthing.

04 Lightning protection

All buildings and plant structures vulnerable to lightning strokes owing to their height or
exposed situation shall be protected against atmospheric flash-overs and lightning
strokes in such a manner as to eliminate any danger to the personnel employed
therein. Stipulations of IS : 2309 - 1969 shall be followed.
A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and
steel structures crossing this cage ring shall be laid around each main building or plant
unit as earthing device. This shall be separate from the electrical equipment earthing
ring main.
All lightning arrestor earth leads of the buildings and plant units shall be connected to
this cage ring.
Air termination network should cover all salient points of the structure. All metallic
chimneys, ducts and the like above the roof of the structure shall be bonded to and
form part of the air termination network. Vertical air termination points shall project at
least 30 cm above the object on which it is fixed.
Down conductors shall follow the most direct path possible between air termination and
earth termination avoiding sharp bends. Down conductor shall have a testing point
adjacent to the earth electrode. Each conductor shall have an independent earth
termination. All earth terminations shall be interconnected.
Earthing electrodes and grid for lightning protection will be distinct separate from the
earthing system for earthing of electrical equipment and at no place will be connected
to other earthing system.
Earthing connection to equipment subject to movement, vibration and shocks, shall be
through flexible stranded conductors.

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The termination of strips to the equipment shall be done by bolting and the wires shall
be terminated by compression lugs. Jointing of strips shall be done by welding for
proper continuity. All contact surfaces shall be thoroughly cleaned of dust and oil and
after jointing, the joints shall be given bitumen paint.

Earthing conductors laid directly in ground, shall be coated with one coat of bituminised
paints, be wrapped with one layer of bitumaetic tape laid on half lapped and shall have
a final coat of bituminised paint to prevent corrosion.
Earthing conductors run on walls/floors/cable and equipment structures etc. shall be
supported at suitable intervals and painted with black oxide paint.

All joints in the branch connections except at earthing electrode shall be welded and
painted black.
At road /rail crossings earthing strips shall be laid through conduits /concrete ducts.
Special earthing shall be provided for all electronic equipment as per manufacturer's
recommendations / practice.

1.02.23 Repair network

01 General

A repair network shall be laid to cover all the units/buildings of main technological plant
for providing power to maintenance tools, tackles and telphers.

Welding switch socket outlets shall be provided at every 60m distance in conveyer
galleries and atleast one at every working platform of junction houses. The number of
welding socket outlets for main technological plant units shall be decided based on
requirement, approach etc. Generally the socket outlets shall be provided in such a
manner so that using 30m flexible cable with welding set, total plant area can be
covered. Upto three switch socket outlets can be looped per feeder circuit. Sheet
metal clad switch units shall be provided for feeding power to telphers.

02 Switch socket outlets

- 415V, 100 A, 3 pole load break switch
- 3 phase and one earth pin socket
- Switch socket interlocked so as to prevent insertion or withdrawal of plug when
switch is "ON".
- Facilities for terminating two cables of 3.5 x 70 sq. mm aluminium cables.
- All the switch socket outlet shall be fed from PDB directly .

03 Cables

- Outgoing feeders to switch sockets 3.5 x 70 sq. -mm for 100A sockets,

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- Outgoing to telphers as per requirement.

1.02.24 Ventilation and Air-Conditioning of Electrical Premises/Control Rooms

01 General

The control rooms shall be provided with air conditioning system. For central control
rooms of standby air conditioners shall also be provided.
Rooms for shift in-charge and office in-charges shall be provided with package AC units.

Separate room, as part of control room shall be provided to house AC units.
The ventilation and air-conditioning system supplied shall be complete with all necessary
central air-conditioning plants (morden microcomputer based), packaged air-conditioners
(micro-computer based), fresh air filters, fan units, supply and return air ducts, monitoring
and regulating equipment and electrical power supply equipment to complete the job
complete in all respects.

Necessary safety interlocks shall be provided to stop the fans/AC system in case of fire
and to prevent spread of fire.

Window / package Air conditioners: Energy savers with temperature sensors / Time
switches for switching ON/OFF of compressor motors.

The equipment shall meet the requirement listed in equipment specification under part-I.

02 Switchgear rooms, MCC rooms, Cable cellar

All HT/LT substations, switchgear rooms and MCC rooms, cable basement/cellars which
do not house any electronic equipment but contain only electrical equipment, shall be
pressurised with cooled washed air to maintain the room temperature within 45 deg.C
irrespective of outer temperature . This shall match with the duty conditions of electrical
equipment in the rooms. Where a large number of electrical equipment are involved,
adiabatically cooled air washer system shall be provided to maintain room temperature at
40deg.C. Suitable capacity fan and pumps (1W+1S) shall be provided for each unit.
Necessary ducts shall be supplied by tenderer.

03 Electrical rooms with electronic equipment

The electrical rooms housing electronic equipment, Remote I/Os, electronic weighing
panels including telephone exchange equipment shall be air-conditioned with
pressurisation to maintain the following conditions:

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- Room temperature : 30 Deg.C

- Relative humidity : Not more than 50 %

- Pressurisation : 2-3 mm WC

04 Central Control rooms, Rooms for PLC, Servers, Computers and Level-1/2
automation system equipment.

These rooms shall be air-conditioned with pressurisation to maintain the following
conditions:

- Room temperature : 21 to 24Deg. C
- Relative humidity : 50 to 60%
- Temperature gradient: 2 Deg. C/h

05 Small local Control Rooms/pulpits

The control rooms/pulpits shall be air-conditioned to maintain the following conditions:

- Room temperature : 24Deg. C
- Relative humidity : 50-60%

06 Cable tunnels and basements

These shall be ventilated with fresh filtered air to maintain temperature of air at exit so
as not to exceed 45 deg.C and pressurised - ventilation of cable basements and
tunnels shall not be combined with other premises.
Cable tunnel ventilation shall be sectionalised to maximum length of 150m.
Temperature rise shall be limited to 3-5 deg. C above atmospheric dry bulb
temperature subject to a maximum of 45 deg.C at the exit of air from these premises.
Ventilation and air conditioning system shall be interlocked with fire detection system
for safety.

1.02.25 Testing
Test of all equipment shall be conducted as per latest ISS/ IPSS applicable. Tests shall
also confirm to International Standards IEC/VDE/DIN/BS (in case corresponding test
are not mentioned in ISS/ IPSS).

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All routine test shall be carried out at manufacturers works in the presence of
purchaser or his representative.
The tenderer shall submit type test certificates for similar equipment supplied by him
elsewhere. In case type test certificates for similar equipment are not available, the
same shall be conducted in the presence of purchaser or his representative if
purchaser so desires, without any financial implications to the purchaser.
All the equipment shall be tested at site to know its condition and to prove suitability for
required performance. The site tests and acceptance tests to be performed by
Contractor are detailed below.
The Contractor shall be responsible for satisfactory working of the complete system in
an integrated manner and its guaranteed performance.

1.02.25.01 Type & Routine
.01 Transformers
A. Routine Tests
viii) Assembly inspection/ Painting check
ix) Measurement of winding resistance
x) Measurement of voltage ratio and check of voltage vector relationship
xi) Measurement of impedance voltage (Principal tapping), short circuit
impedance and load loss.
xii) Measurement of no-load and current.
vi) Measurement of insulation resistance/ polarizatation index.
xiii) Dielectric test:
a) Induced over voltage withstand test
b) Applied voltage withstand test
(H.V. power frequency test)
xiv) Certification for off-load tap changer
xv) Final documentation check
B. Type Tests
i) Temperature rise test
ii) Measurement of acoustic sound level
iii) Lightning impulse withstand test (if test certificates are not available)
iv) Short circuit test
v) Measurement of commutating reactance and determination of inductive
voltage drops (for thyristor converter transformer only).

.02 Busduct
A. Routine Tests
i) One min. power freq. withstand voltage

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ii) Measurement of insulation resistance
iii) Measurement of resistance and reactance of busbars
B. Type Tests
i) Heat run test
ii) Short time rating test (thermal & dynamic)
iii) Impulse withstand test
iv) Tests for degree of protection for enclosures

.03 Power Control Centre and LT switchgear
A. Routine Tests
i) Assembly inspection/ Painting check
ii) Measurement of insulation resistance
iii) Dielectric test for assembled unit
iv) Functional test including automatic bus transfer scheme
v) Tests of ACBs including operation test, calibration of releases, measurements
of contact resistances.
vi) Polarity tests for CTs.
vii) Final documentation check
B. Type Tests
i) Temperature rise test for main and vertical bus-bars.
ii) Short-circuit test for main and vertical bus-bars.
iii) Enclosure class, degree of protection
iv) Dielectric test including protective circuit.

.04 Load Break Isolator
A. Routine Tests
i) Assembly inspection/ surface treatment check
ii) Power frequency voltage withstand dry test on the main circuit.
iii) Voltage withstand test on auxiliary and control circuits.
iv) Check of the main circuit
v) Mechanical operating test
vi) Insulation resistance measurement
vii) Contact resistance
viii) High voltage test
ix) Final documentation check
B. Type Tests
i) Type test for typical isolator and/ or earthing switches

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ii) Temp. rise test of contact
.05 Current Transformer and voltage transformer
A. Routine Tests
i) Assembly inspection
ii) Power-frequency tests on primary windings
iii) Power-frequency tests on secondary windings
iv) Over-voltage inter-turn tests
v) Dielectric test
vi) Ratio & polarity test
vii) Measurement of ratio error & phase angle error
viii) VI characteristics
ix) PT winding resistance
x) Final documentation check
B. Type Tests
i) Short-time current test
ii) Temperature rise test
.06 Final Test of Materials of Grounding and lightning system
i) Visual check
ii) Dimensional check
iii) Accessories fitting check
iv) Mechanical and electrical test (where applicable)
v) Final documentation check
07 CABLES
1. Shop Tests

a) The cables shall be subject to shop tests in accordance with relevant
standards to prove the design and general qualities of the cables as
below:-

b) Routine test on each drum of cables

2. Acceptance tests on drum chosen at random for acceptance of the lot

a) High Voltage withstand test for HT cable (Hi Pot test)

b) Type tests certificates on each type of cable, inclusive of measurement of
armour D.C. resistance of power cables will be furnished by Contractor

B. PACKING

1. Cables will suit barrel diameter and securely clamped/fixed. The barrels must
be sufficiently strong to withstand mechanical shocks and shall effectively
protect against transit.

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2. Both ends of cable will be metal capped to prevent moisture ingression.
Ends shall be kept inside the cable drum in a manner so that these are
accessible for testing.

3. Cable drum identification/marking will be as follows:

a) Makers name
b) Consignees full address
c) Type size and length of cables
d) Net and gross weights
e) Any other marking for shipping
f) Drum Markings

C. Drum Lengths

1. LT Cables will be delivered at site preferably on standard drums each
containing 500 m or 1000 m cables, Where total quantity of a particular cable
is less than 500 m, the entire length will be supplied in one drum.

2. For 90% cable drum of each item of cable permissible tolerance is in length
+ 5% For 10% balance cable drums, Contractor shall ensure that each 500
m capacity drum contains at least 250m and each 1000m capacity drum
contains at least 500m cable lengths. Overall tolerance for each item of
cable is + 1% of total length.

08. Motors :-
A. Routine Tests
The following are the routine tests carried out on each and every motor :
1.0 Measurement of resistance.
2.0 Insulation resistance test .
3.0 Motors are tested at 1/3 times the rated voltage for checking the ability of the
motor to run upto full speed , when switched in either direction .
4.0 No load test .
5.0 High voltage test .
B. Type Tests
1 Measurement of rotor resistance .
2 No load test
3 Locked rotor test .
4 Full load reading of voltage, current , power input and slip.
5 Temperature rise test.
6 Momentary overload test .
7 Insulation resistance test .
8 High voltage test .
9 Polarisation index test (for HT motors)

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09 SITE TESTS AND CHECKS
001 General
All the equipment will be tested at site to know their condition and to prove suitability for
required performance.
The test indicated in following pages will be conducted after installation. All tools,
accessories and required instruments will have to be arranged by contractor. Any
other test that is considered necessary by the manufacturer of the equipment,
Contractor or mentioned in commissioning manual has to be conducted at site.
In addition to tests on individual equipment some tests / checks are to be conducted /
observed from overall system point of view. Such checks are highlighted under
miscellaneous tests but these will not be limited to as indicated and will be finalised
with consultation of client before charging of the system.
The Contractor will be responsible for satisfactory working of complete integrated
system and guaranteed performance.
All checks and tests will be conducted in the presence of Clients representative and
test results will be submitted in six copies to Client and one copy to Electrical Inspector.
Test results will be filled in proper proforma.
After clearance from Electrical Inspector, system / equipment will be charged in step by
step method.
Based on the test results clear cut observation will be indicated by testing engineer with
regard to suitability for charging of the equipment or reasons for not charging are to be
brought by the Contractor.

002 Trial Run Test
After the successful test of each equipment as per standard test procedure, the entire
control system will be put on trial run test on actual site conditions and operation of the
system.

003 Acceptance Test
The acceptance test on the system will be carried out by the contractor as per mutually
agreed test procedures to establish satisfactorily functioning of the system as a whole
and each equipment as part of the system.

004 Site Tests

The tests to be carried out on the equipment at pre-commissioning stage will include
following but not limited to the following:

Transformer
1
IR test on each winding to ground and between winding and check for polarization index.
2
Turns ratio test on each tap
3
Polarity and vector group test
4
Measurement of winding resistance for windings by Kelvin bridge.
5
Heating and drying and checking with heating and cooling curve.

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6
Checking of earthing wrt transformer tank (flexible from top cover to tank) other parts,
neutrals and tank to electrodes of LAs (for LAs located near transformer)..
7.
Testing of Buchholtz relay for alarm and trip conditions
8.
For bushing CTs, tests applicable will be as for current transformers.
9.
Calibration and setting of oil/winding temperature indicators, level gauge
10
Check insulators for cracks.
11
Checking for oil leakage and arresting of leakages (if required)
12.
Checking of operation of all valves.
13
Checking of open operation of all valves (except drain and filter set)
14
Filtration of oil by using line filter and heater set
15
BDV test on Oil samples from top & bottom
16
Checking of Oil for acidity, water content and tan delta as per IS 335.
17.
Measurement of magnetising current and no load loss.
18.
Checking of silica gel breather.
19.
Checking of noise level at no load and at full load.
20.
Checking of air circulation conditions for indoor transformers.
21.
Conducting magnetic balance test.
22.
Checking of other points given in manufacturers commissioning manuals.
23.
IR, wiring and operational tests on all control devices in control cabinet, oil level indicator
winding and oil temp. indicators, oil pump, cooling fan etc.

HT ISOLATOR
1.
IR test before & after HV test
2.
HV test
3.
Operational test
4.
Checking of interlocking with earth switch
5.
Checking of operation of earth switch
6.
Checking of tightness of earth connection
7.
Check for continuity of aux contacts

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8.
Check working of shunt trip (if applicable)
9.
Checking of CTs, PTs (if applicable) as per the details given in HT board.
10.
Contact resistance/ millivolt drop test

LT SWITCHBOARD
1.
2.
3.
4.
5.

6.
7.
8.
9.

10.

11.

12.

13.

14.
IR test
HV test with 2.5 kV megger
Functional test for all feeders
Testing and calibration of all meters
Checking and calibration of overload relays and protective relays by primary injection
method.
Check operation of contactors from local and remote points.
Checking of interlocking between incomers/ bus couplers and other feeders
Test of prove interchangeability of similar parts.
Test to prove correct operation of breakers at minimum and maximum specified control
voltages.
Checking operation of RC circuit (if there) for tripping of circuit breaker after
disappearance of control voltage.
Checking of earthing connection for neutral-earth bus, cable armour, location of E/F CT
etc. as per the scheme.
Checking of tests, service and drawout position of all the breakers and operations of
mechanical flag indicator and electrical indication lamps.
Checking the functioning of various electrical schemes like auto change over, signaling
etc.
Contact pressure test

BUS DUCTS
1.
IR measurement before and after HV test.
2.
HV test.
3.
Checking tightness of bolts with torque wrench.
4.
Checking for phase sequence marking.
5.
Check for clearances between phase to phase and phase to earth.
6.
Check for minor damages and cracks in supporting insulators and bushings after
cleaning.
7.
Checking of busbar cracks and rectification of same.

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8.
Checking for inspection openings and accessibility for replacement of insulator etc.
9.
Check tightness of earthing connections on enclosure.
10.
Checking of silicagel breather (if there).
11.
Checking of working of space heater.
12.
Hot air blowing to remove moisture if required.

Cables
1.
Visual check
.2
Checking of continuity and IR values for all the cables before and after HV test.
.3
HV test and measurement of leakage current after termination of cable kits (for HT
cables).
.4
Checking of earth continuity for armour and fourth core (if applicable)
.5
Check for mechanical protection of cables.
.6
Check for identification (tag number system) distance placement of cable marker, cable
joint etc. as per the cable layout drawing.
.7
Check earthing of cable structures.
.8
Check safe head room in tunnel and basement area.
.9
Check clearance from ventilation duct and light fittings for cable structures.
.10
Check proper fixing of cable structures.
.11
Check for proper drainage and removal of water (if any).

Lightning Protection
.1
Check continuity of all the earth strips / shield wire.
.2
Check tightness of all connections.
.3
Measure earth resistance of each electrode and combined system.

Earthing
.1
Check tightness of all earth connections.
.2
Check earthing of all metallic equipments, cable trays, busbar supporting structures,
building column (if steel) all elect equipments, pipe lines etc. as per the drawing /
specification
.3
Measurement of earth resistance for each electrode.
.4
Measurement of total earth resistance.

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.5
Measurement of earth loop resistance for E/F path of biggest LT drive.

Miscellaneous
.1
Checking of continuity of the system.
.2
Checking of phase sequence from overhead line consumer end.
.3
Checking safe accessibility of all operating points
.4
Check availability of emergency lighting
.5
Check availability of control aux. supply.
.6
Ensure availability of first aid box, fire fighting equipments, earth discharge rods, rubber
mats, rubber glove.
.7
Check oil drainage system for transformer oil
.8
Check filling of gravels in transformer pits.
.9
Check for safe movement of operators control room / switchgear etc., wrt proper
illumination, escape light uncovered openings provision of hand railings in stairs etc.
.10
Check proper covering of cable channels.
.11
Placement of shock treatment chart, danger boards provision of boards indicating Man
on work Do not switch ON Do not switch OFF. EARTHED etc.
.12
Provision of route map at gallery entry points for indication of escape.
.14
Check proper dressing of cables, mechanical protection of cables, placement of cable
markers.
.15
Check sealing of all cable openings including conduits opening with fire resistance
material.
.16
Check sealing of all openings at bottom of electrical panels.

APPENDIX

TABLE - I

SELECTION OF POWER COMPONENTS & WIRING FOR CONTINUOUS DUTY CAGE MOTOR
DRIVES

Rating of MCCB / MPCB as required shall be selected based on type-2 protection.

Motor rating at S1
duty (kW)
Minimum rating
of MCCB in
Amps (AC23)
Minimum rating
of Power
contactor Amps
(AC3)
Minimum size of
Cu wire / flat in sq.
mm for internal
power connection
Minimum size of
Power cable (Al.)
termination in
sq.mm.

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Up to 3.7 (DOL) 32 32 4 4x2.5 Cu.
Up to 3.7 (RDOL) 32 32 4 4X2.5 Cu.
5.5 32 32 4 4X6
7.5 63 32 4 4X6
11 63 45 6 4X10
15 63 45 10 4X16
18.5 63 70 16 4X35
22 125 70 16 4X35
30 125 110 35 3.5X50
37 125 110 35 3.5X50
45 250 170 50 3.5X95
55 250 170 70 3.5X120
75 250 250 95 3.5X185
90 250 250 30X5 Flat 2(3.5X120)
110 400 400 30x5 Flat 2(3.5x120)
125/132 400 400 30x5 Flat 2(3.5x120)
160 400 630 40x5 2(3.5x185)
180/200 630 630 30x10 3(3.5x185)

1.02.27 ILLUMINATION
1.0 General
The lighting system inside and outside plant units are designed based on the desired
illumination levels recommended by IS and the practices followed in industries,
architectural arrangement, building dimensions including mounting height, environmental
considerations, ease of maintenance and reliability of the lighting distribution network.

2.0 The illumination system shall be designed as per IS:3646-1992. The level of illumination,
type of fittings, maintenance factor to be considered is as given below:

Area Type of Light Fittings Lux
level
MF
Control rooms Louvered recessed type 2x40W & 4x20W
fluorescent fittings
300 0.75
Electrical rooms having
PDB, MCC, VFD panels,
PLC
Industrial corrosion proof fluorescent lamp
fittings for 2x36W fluorescent lamps
Philips type TKC 22/236 or equivalent
200 0.7
Staircases of plant buildings - do - 70 0.6
Staircases (steel) of plant Industrial well-glass integral type luminaire 70 0.6

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complex and cable tunnels /
cellars
suitable for 70W HPSV lamps, similar to
Philips type SDL-23/70 or equivalent
Pump house - do - 200 0.6
Flood lighting Weather proof flood light fittings for
1x400W HPSV lamps Philips type
H/SVF12 or equivalent
70 0.5
Pipeline tunnel Industrial fittings for 24V, 2x50W halogen
lamps Sigma make deck lights or eqvt.

Casting Bay High bay HPSV industrial incandescent
(1000 W) equivalent to HDK /SDK of
PHILLIPS make
200
Conveyor Houses /
conveyor gantries / junction
houses
Fluorescent / incandescent industrial type
fitting equivalent to TPW / NXC of
PHILLIPS make
70 to
100

Aviation obstruction Aviation obstruction light fittings, flame
retardant type consisting of multi ultra high
intensity 60 mscp LED module, without
flashing module, steady in red colour,
having omni directional capability and
shall be suitable to deliver maximum light
output in the zone between 70 above and
10 below the horizontal with a maximum
of condition at 20 above the module.

a)Standard wattage of lamps shall be
1.FTL
36 W high luminous lamps.
2. HPMV
250 and 400 W
3. HPSV
70, 150, 250 and 400 W
4.Incandescent
60, 100 W (Use of Incandescent lamps shall be avoided )
b) Compact fluorescent lamps are to be used for offices and corridors.
c) All switches and sockets used in office buildings shall be of flush type
d) For street lighting, necessary control gear shall be provided for reduced voltage running during
off peak traffic for energy conservation.

Illumination: Electronic ballast having third harmonic distortion less than 6 % and total harmonic
distortion less than 12 % with high luminous tube lights are to used. Time switches, reduced
voltage controllers, group solar lighting sections for remote areas shall be provide wherever
feasible. Lighting Fixtures and Accessories shall be energy efficient

3.0 Area Lighting :-

Classification
Type of road Av. Lux
level
Type of
illumination
MF

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Group - A1 Important traffic road
carrying fast traffic
30 Cut off / semi cut
off

0.6
Group - A2 Main road carrying
mixed traffic
off
0.6
Group - B1 Secondary road with
considerable traffic
off or non cut off
0.6
Group - B2 Secondary road with
light traffic
off or non cut off
0.6

MF : Maintenance factor

The light fittings shall be complete with all accessories like electronic ballast, reflector etc.
External area lighting including street/road lighting / tower lights shall be fed from MLDB through
separate SLDB located at suitable places. Automatic switching ON/OFF of these circuits shall be
done through timers. Flood light towers shall be fed through 415/240V, 3 phase, 4 wire circuit with
individual fittings distributed at 240V, single phase, with control and protection located at bottom
of each tower. Rewireable fuse in a sheet steel box shall be provided near each fitting to facilitate
removal of lamp in off position.
In high bays walkway shall be provided for maintaining light fittings. At other places suitable
ladder/platform/approach shall be provided for maintaining/replacement of light fittings.

B. Power distribution
1.0 The distribution of lighting power supply for the individual areas shall be done at 415V, 3 phase,
4 wire bus system through Main Lighting Distribution Boards (MLDB) for the area. The MLDB
shall be fed through a lighting transformer . The outgoing feeders of the MLDB shall feed the
required numbers of Sub Lighting Distribution Boards (SLDB) for lighting. Each SLDB shall
receive power at 415V AC, 3 phase, 4 wire and distribute it into 240V, 1 phase circuits for
connection to the lighting fixtures and 240V receptacles. The SLDB shall be located in the
rooms, bays etc. covering the respective zone. The SLDB shall be located in the electrical
rooms in the respective area.

2.0 Emergency lighting

In case of indoor illumination, separate lighting circuit shall be provided as emergency lighting
circuit. Emergency lighting circuit shall be through emergency MCC/PDBs so that in case of
failure of power in lighting DBs circuit, these lights can continue to glow. 20% lights shall be
connected to this circuit. Balance lights shall be connected through lighting circuit.
Portable Emergency lighting including built-in battery, battery charger & lamps shall be provided
in strategic areas like control rooms, staircases, entry of cable tunnels/basements, escape
routes, etc. for safety.

3.0 Maintenance lighting
For maintenance lighting, power supply shall be fed from 240/26.5V small capacity step-down
transformers to the 24V socket outlets.

4.0 Outdoor lighting

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Flood lights for area lighting shall be mounted on towers/poles or building structures. Tower
height shall be kept to an average of 22m.
Street/road lighting and boundary wall lighting shall be provided with HPSV/fluorescent lamp
fittings mounted on poles of 9m to 11m height.
Neon aviation obstruction lights shall be provided on chimneys and other such tall installations
as per regulation. M/S Binay or equivalent make aviation obstruction lights( LED type ) shall be
provided . For street lighting necessary control gear shall be provided for reduced voltage
running during off peak traffic for energy conservation .

5.0 Power factor improvement
Power factor of all the light fittings shall be improved so that it is not less than 0.90. Power factor
shall be improved by providing capacitor banks with discharge resistor in the light distribution or
by providing capacitors with individual fittings.

C. SPECIFICATIONS :-

A. EQUIPMENTS AND COMPONENTS

1 Lighting Transformer

1.0 Type Dry Type
2.0 Power Rating As per load calculation
3.0 Primary Voltage 415 V
4.0 Secondary Voltage 415 V
5.0 Connection Star - Star

2.0 Main Lighting Distribution Board (MLDB)

A. General
- Non drawout type.
- Fully compartmentalized with metal / insulating
material partition.
3.0 Enclosure class IP52
Sheet steel
1.0
Material CRCA
3.0 Design - Separate bus alley and cable alley on opposite side of
the outgoing modules .

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- Each module to have covering at the bottom.
4.0 Interlocking & protection - Module door interlocked with main power isolating
devices.
- Power circuit isolation device to have pad locking in
the OFF position with door closed.
(3 mm thick)
doors , removable covers & between adjacent
covers .
8.0 Labelling Clear legible identification labels (anodized aluminium
with white letters engraved on black background ) with
letter sizes of :-
- 25-50 mm for MLDB panel
- Bolted joints with tooth spring washers for good earth
continuity.
- Earth bus to run in all cable alley of the panel .
10.0 Shipping length To be limited to 2.4 M.
11.0 Limiting dimensions - Width of MLDB :- 2400 mm
- Depth of MLDB :- 500 mm
- Width of Cable alley :- 300 mm
- Width of Bus alley :- 300 mm
- Height of module :- 400 mm (min)
12.0 Paint shade Shade No. 631 as per IS-5:1992.
C. Busbars
(i) Main horizontal & vertical busbars
2.0 Material High conductivity electrolytic aluminium alloy confirming
to grade E91E as per IS-5082 1981.
3.0 Phase Busbar Rating - Shall be able to carry continuously the connected
margin .
6.0 Busbar configuration Red-yellow-blue from front to back or top to bottom or
left to right as viewed from front.
insulators
- Non-hygroscopic
- Flame retarded

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- Track resistant
- High strength
- Sheet moulded compound or equivalent polyster
9.0 Max. temp. rise of bus Not to exceed 35 deg. C. above ambient of 50 deg.C.
busbar
11.0 Joints and tap off points - Busbar joints and tap off points shall be shrouded
and bolted ( with cadmium coated bolts with plain
and spring washers and locknuts).
- Bimetallic connectors for connection between
dissimilar metals .
- Antioxide grease for all bus connections .
13.0 Vertical busbar Rear side
(ii) Earth bus
1.0 Material GI.
2.0 Size Minimum 50 x 6 mm with extension at both ends .
(iii) Control bus
D. Insulation level
1.0 Rated insulation voltage 1100 V
2.0 Impulse withstand voltage 4 KV as per IS-13947 (Part I) 1993
frequency withstand voltage
2.5 KV for power circuit & 500 V for control circuit
E. Pollution Degree
as per IS-13947 (Part-1) : 1993 ;
Incomers

3 pole MCCB (for rating upto 630 A)
(with E/F protection).
2.0 Quantity Two incomer
3.0 Autochangeover - Through contactor logic with suitable timer.
- Normally only one Incomer shall be ON .
- MCCB ON/OFF/TRIP.
switches
- 144 sq.mm size voltmeter with 7 position selector
switches
- 144 sq.mm size ammeter with 4 position selector
switches

6.0 Current transformer 3 numbers for metering .
Outgoing feeder arrangements
1.0 Circuit breaker Three pole MCCB .
2.0 Indications ON/OFF/TRIP indication lamp.
3.0 Protection All the equipment inside the boards shall be covered in
front with a 3 mm thick bakelite sheet. Only the
operating knobs of the equipment shall be projected
outside the bakelite sheet for safe operation.

BHILAI STEEL PLANT


G. Panel wiring
1.0 Power / current transformer
circuit
stranded copper conductor of minimum size 2.5
sq.mm.
- Power terminals will be stud type.
- Control terminals will be ELMEX type suitable for
- The minimum rating of control terminal shall be 10
Amps.

3.0 SUB LIGHTING DISTRIBUTION BOARD (SLDB)

1.0 Type - Metal clad
- Shall be suitable for 415/240V, 3 phase and neutral.
2.0 Construction - Totally enclosed.
- Dust & vermin proof.
- Welded back and sides .
3.0 Enclosure class IP54 .
IP 55 (with canopy) for outdoor installation .
5.0 Mounting Wall mounting .
6.0 Installation Indoor / Outdoor (with canopy).
Sheet steel CRCA 1.0
Thickness 2 mm .
- Outgoing :- Top / Bottom cable entry.
3.0 Design - One Incomer and outgoings .
- Access to the operating handle of the incoming
isolating switch shall be from the front of the cubicle
without opening the front door.
- Operating knobs of outgoing MCBs shall be
accessible only after opening the front door of the
cubicle.
- Protective insulated cover plate (3 mm thick bakelite
sheet ) shall be provided inside the cubicle to shroud
all the live parts .
4.0 Gland plate Undrilled detachable gland plates (3 mm thick) shall be
provided at the top and bottom with suitable gaskets for
cable entry.
doors , removable covers & between adjacent
covers .
- Suitable locking devices.

BHILAI STEEL PLANT


6.0 Labelling Clear legible identification labels (anodized aluminium
with white letters engraved on black background ) with
letter sizes of :-
7.0 Earthing Two separate earthing terminals will be provided.
8.0 Limiting dimensions - Width of SLDB :- 800 mm
- Depth of SLDB :- 300 mm
- Height of SLDB :- 400 mm (min)
9.0 Paint shade Shade No. 631 as per IS-5:1992.
C. Busbars
2.0 Material High conductivity electrolytic aluminium alloy confirming
to grade E91E as per IS-5082 1981.
3.0 Phase Busbar Rating - Shall be able to carry continuously the connected
margin .
6.0 Busbar configuration Red-yellow-blue , black for neutral .
insulators
- Non-hygroscopic
- Flame retarded
- Track resistant
- High strength
- Sheet moulded compound or equivalent polyster
busbar
Incomers

3 pole ELCB
ELCB shall be of AC 23 duty category conforming to IS:
13947-1993 having fully shrouded contacts.
2.0 Quantity One
Outgoing feeder arrangements
1.0 Circuit breaker DP MCB
G. Panel wiring
1.0 Power / current transformer
circuit
stranded copper conductor of minimum size 2.5
sq.mm.

BHILAI STEEL PLANT


- Terminals shall be ELMEX type suitable for
- The minimum rating of control terminal shall be 10
Amps.
5.0 Cable glands Double compression cable glands for receiving cables .

4.0 Control Room Switchboard
1.0 Location Control room for controlling the lighting fixtures
2.0 Type Flush mounted type
3.0 Construction Fabricated from 14 SWG MS sheet with 6mm thick
bakelite cover
Shall have conduct knockouts on the sides.
4.0 Switch mechanism Quick make and quick break mechanism
5.0 Power source The switchboards shall be fed from SLDB of respective
area.

5.0 Transformer for 24V AC Sockets :-

1.0 Type Dry type
Step-down transformer
Air-cooled
2.0 Rating Minimum 2500VA
3.0 Primary / secondary voltage 240V /26.5 V AC , single-phase
4.0 Construction The transformer shall be enclosed in industrial wall
mounting stainless steel (2 mm thick) box having
separate chambers for the transformer, incoming and
outgoing MCBs.
5.0 Cable entry Suitable knock-outs shall be provided at the top and
bottom for cable entry through GI pipes.
6.0 No. of winding Two winding
7.0 Protection SPN MCBs on primary and secondary side
incorporating overload and short circuit releases.
8.0 Utility Power supply to 24V repair network
9.0 Location On structural platforms

6.0 24 V AC SWITCH SOCKET OUTLET
1.0 Type 2 pole, 3 pin with third pin earthed industrial type
receptacles
2.0 Rating 24 V AC , 5A,
3.0 Construction Metal clad gasketted construction, weatherproof
4.0 Cable entry Suitable for cable entry through 20mm dia. conduit.
5.0 Mounting Wall / column mounting

7.0 240V SWITCH SOCKET OUTLET
1.0 Type 1 pole, 3 pin with third pin earthed industrial type
receptacles .
non-reversible, metal-clad, dust proof, industrial type
suitable for horizontal insertion.
2.0 Rating 240 V AC , 15A,
3.0 Construction Metal clad gasketted construction, weatherproof

BHILAI STEEL PLANT


All socket outlets will be supplied with heavy-duty type
plug and cap with chain.
4.0 Isolation Switch rotary type switch mounted flush in the socket outlet
box.
The isolating switches will be manually operated
industrial type of category AC 22.
5.0 Protection Operating handle of the rotary switch will be fixed in
such a manner that it will not be possible either to insert
or withdraw the plug without switching off the supply.
6.0 Cable entry Suitable for cable entry through 20mm dia. conduit.
7.0 Mounting Wall / column mounting
8.0 Inscription Inscription plate will be provided indicating the voltage
and current rating of the switch socket outlet.
9.0 Miscellaneous In hazardous area, flame proof switch socket outlet will
be provided.

8.0 Miniature Circuit Breakers
1.0 Type Heat resistant plastic moulded type
2.0 Ref . Standard IS: 8828 1978
3.0 Protections MCBs shall be provided with quick break trip-free
mechanism and direct acting thermal overload and
short circuit trip elements.
4.0 Short circuit capacity Not less than 9000A at 0.8pf
Single phase MCBs mounted adjacent to each other
and connected to different phases will be provided with
6.0 Current Rating The MCBs shall be selected from standard current
ratings.(Asper SLD)
MCB shall confirm to curve C .
Motor duty MCBs will be provided, if specified.

9.0 240 V SINGLE/ DOUBLE POLE SWITCHES
1.0 Application The switches are intended for controlling lighting
circuits
2.0 Type Weather and dustproof and industrial type
3.0 Design The rotary or toggle switches provided will be of sturdy
design
4.0 Standard As per IS : 6875 (Part-3) - 1980
5.0 Housing The unit will be housed in cast iron or cast aluminium
box having gasketted, screwed front cover plate, fixing
lugs and suitable provision for terminating conduit/cable
at the top, bottom or sides as specified.
Single phase MCBs mounted adjacent to each other
and connected to different phases will be provided with
7.0 Terminal suitability Terminals suitable for aluminium conductor cables.

B. Cabling and Wiring
01 All wiring from SLDB to lighting fixtures and receptacles shall be carried out with 1100V / 650V
grade PVC insulated and PVC sheathed unarmoured cable in MS / GI pipes. For each
outgoing phase conductor from the MCB of SLDB, one no. neutral conductor shall be taken

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc 2UU o 2U5
from the same SLDB and shall run along with the phase conductor throughout the length of
the cable run upto the luminaires.
02 All lighting cables for the entire complex shall be PVC insulated with copper conductors .
C. Lighting Fixtures and Accessories
01 All the luminaires will be designed, manufactured and tested in accordance with the Indian
Standards in so far as they are applicable. Lighting Fixtures and Accessories shall be energy
efficient
02 All the luminaires will be industrial type. Specification for the various types of sodium vapour
and fluorescent fittings mentioned in the schedule of quantities will be followed. All the
lighting fixtures will be complete with all parts along with lamps/tubes, control gears and
accessories for installation and efficient performance whether specifically mentioned in the
specification or in the schedule of items or not.
03 Individual light fittings will be provided with suitable gland arrangements for 3x2.5 sq.mm
armoured copper cable entry unless otherwise specified. Terminals of all fittings will be
suitable for taking 3x2.5 sq.mm, copper conductor PVC insulated and PVC sheathed cable.
04 All fittings will be supplied with all interconnections made and fully wired upto the terminal block.
05 All live parts will be provided with suitable sleeves to prevent accidental contacts. The earthing
terminal in the fitting will effectively earth the body of the entire luminaire.
06 Dust and vapour tight fittings will have the enclosures suitably designed to withstand the heating
effect.
07 The fixing arrangement of various components and lamps will be in such a way that the
maintenance and replacement jobs can be easily carried out.
08 All flameproof equipment will be provided with flameproof plugs.
09 Flame proof fittings and control gearboxes will be provided as per relevant IS in hazardous
area.
D. ILLUMINATION FITTINGS
1.0 OUTDOOR LIGHTING FITTINGS.
All road lighting fittings will be mounted on steel tubular poles with single/ double or triple
outreach brackets having sodium vapour lamps. The fittings will be cut-off / semi cut-off
distribution and integral type.
For lighting of open areas self-supporting steel towers shall be provided with flood light fittings
and sodium vapour lamps.
2.0 FLUORESCENT FITTINGS
2.01 DECORATIVE FLUORESCENT LIGHT FITTING
Decorative type fluorescent tube light fitting complete with stove enamelled mounting rail,
polyester filled ballast, spring loaded rotor lamp holders, starter holder and starter, power
factor correction condenser to improve the power factor to 0.95 and acrylic diffuser. Provision
will be made for mounting the fitting end to end in continuous row and/or for mounting
individually using high impact black polystyrene end plate. All the fluorescent tube lights
fixtures shall have electronic ballast having third harmonic distortion less than 6% and total
harmonic distortion less than 12 % .
2.02 INDUSTRIAL TYPE FLUORESCENT LIGHT FITTING

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc 2Ul o 2U5
The fitting will have channel and reflector made of CRCA sheet steel with white cover plate.
Channel and reflector will be finished with light Grey stove enamelled outside and white stove
enamelled inside. The fitting will be complete with all electrical accessories like polyester filled
ballast, starter, spring loaded rotor lamp holders, starter holder, power factor improvement
capacitor to improve the power factor upto 0.95 etc. All the fluorescent tube lights fixtures shall
have electronic ballast having third harmonic distortion less than 6% and total harmonic
distortion less than 12 % .
All types of fluorescent fittings will be suitable for mounting on wall/ceiling/conduit suspension.
2.02.1 WELL GLASS FITTINGS
Well glass lighting fitting will be fitted with sodium vapour or mercury vapour lamps. These
fittings will be suitable for hanging by means of hangers, brackets, hooks etc. as required. All
fittings will be integral type.
2.02.2 FLOOD LIGHT FITTING
Sodium vapour flood light fittings are required for area lighting as specified in schedule of
quantities.
The Flood light fitting will be weatherproof and suitable for outdoor duty. The
housing/enclosure will be of die cast Aluminium alloy and finished with hammertone Grey.
The enclosure of the luminaries will be provided with a flat toughened glass in the front.
Adequate gasketting will be provided with synthetic rubber for making the luminaries
completely weatherproof. The fitting will be provided with facility to position the luminaries
for effective lighting at the target area. The fitting will also be provided with graduated
protractor to aid accurate aim and ensure a con-trolled light distribution.
High quality polished Aluminium will be used in the reflector to ensure powerful light beams.
The reflector will be anodised to enhance the longevity and contoured in multiple segments
for optimum optical performance. The fitting will be provided with GES porcelain lamp
holder. The control gear housing (separate control gear-non-integral type) will be housed
with copper wound ballast, perfected improvement capacitor and terminal block. An
electronic igniter will be provided in the luminaries.
All the control gear components will be pre-wired in all respects and terminated to the
terminal block for incoming cables. The fitting will be provided with earthing terminal and
wiring will be done by multi-strand copper conductor. All the fasteners will be electroplated
and passivated. The fitting will be suitable for twin/Single 400 watts HPSV lamps.
2.02.3 STREET LIGHT FITTING
Street light fittings will be suitable for outdoor duty in weatherproof, single piece die cast
Aluminium enclosure, finished with epoxy paint outside and stove enamelled inside. The
fitting will be provided with GES porcelain lamp holder, and anodised Aluminium reflector
with facility for obtaining cut off as well as semi-cut off light distribution. These will also be
provided with high transparency clear acrylic cover with neoprene rubber gasket to make
them absolutely dust and weather proof. Control gear compartment will be provided with
detachable CRCA steel, pre-wired with ballast, capacitor, igniter and terminal blocks for
incoming supply, Fittings will be provided with earthing terminals and wiring will be done
with multi-strand copper conductor.

All the fasteners will be electroplated/passivated and mounting arrangement will be suitable
for direct mounting on poles having maximum 65 mm. OD with provision for holding the
pipe in extended portion of control gear by means of clamps
2.02.4 FLAME PROOF FITTINGS

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc 2U2 o 2U5
Flame proof type fittings will be well glass type luminaries suitable for use with HPLN 250W
(High pressure Mercury Vapour) lamp with separate control gear complete with copper
ballast, power factor improvement capacitor, terminal block enabling loop-in-loop out
connection. Both fittings & control gear will be of cast Aluminium alloy LM6 or cast iron
stove enamel, Grey hammertone finish outside and white inside.
The control gear box and enclosure for fittings will have certification from CMRS, Dhanbad
and will be suitable for gas groups IIA & IIB as per IS 2148-1981. The fittings will be
designed as per IS 2206 (Part-I) -1987. The material for cable gland will be brass/stainless
steel/aluminium alloy LM6 and will be double compression type suitable for indoor/outdoor
use. These are must for every flameproof fittings and accessories.
2.02.5 CONTROL GEAR, LAMP & ACCESSORIES
Lamps
Sodium vapour lamps will be suitable for universal burning position. The characteristics of
the lamps will be in line with the relevant Indian Standards. The outer bulbs will be elliptical
hear resistant type, evacuated to minimise heat losses and coated with light diffusion film
for pleasing colour discharge. The lamp will be provided with corrosion resistant, nickel-
plated screw base.
Ballasts
All ballasts will be of proven design and capable of delivering long trouble free service. The
ballasts will be made up of low loss silicon with steel lamination and will be wound with
polyester-based super enamelled copper wire. The ballast will be polyester filled and able
to dissipate the heat efficiently so as to keep the temperature rise well within the limits
specified in the IS.6616-1972. The ballast will be provided with tapping at 200,220 and 240
volts and will be suitable for HPSV lamps.
Capacitors
Capacitors will have element wound from layers of high purity Aluminium foils laid over the
two faces of capacitor paper. The Aluminium cylindrical case containing the elements will
be dried under high vacuum and impregnated before being sealed. The solder type lug
terminals will be mounted over porcelain insulators at the sealed end and the capacitor will
conform to IS: 1569. The value of capacitance will be chosen as to raise the power factor
of burning lamps to above 90%.
Igniters and Starters.
Igniters for HPSV lamps will be of proven design and capable of delivering long trouble free
operations. The igniter and starters will be suitable for tropical condition and conform to IS:
2215-1968.
Lamp and Starter Holders
Lamp and starter holders will have good spring contacts and of well tried out design. The
spring contact will be such as to prevent disconnection due to vibration during cleaning.
They will also have facility for easy removal.
3.0 Street Lighting Poles
Lighting poles will be fabricated from GI of specified section with joints swaged together
when hot and bevelled on outside edges. A weatherproof sheet steel junction box will be
provided at the bottom of the pole and contain fuse, neutral link, bolted type terminals,
grounding stud etc. The bolted type terminals will be suitable for receiving 4 x 16 mm2
AYFY cables with loop-in-loop out arrangement GI conduits will be embedded in the muff
for incoming and outgoing cables.

BHILAI STEEL PLANT


2UU?. MECON Lntcd. A HgIts Hcscucd. Pugc 2UJ o 2U5
The street light poles of 9M height will be conforming to: 410-SP-29
The street light poles of 7M height will be conforming to : 410-SP-3
All erection consumables like bricks, sand, cement stone chips etc. for foundation of poles
will be supplied & erected
4.0 High Mast Lighting Tower
4.01 Mast Proper
The mast will be 30 meters high and designed in such a manner that it is capable of
withstanding external forces exerted by wind pressure as per IS: 875 (Part 3)-1992 along
with load of the lantern carriage assembly.
4.02 Mast Construction
The mast will be fabricated from special steel plates conforming to BS 4360 cut and folded
to form number of polygonal sections, giving a continuous tapered profile for stability and
aesthetics, Silicon content in steel should not exceed 03% for good quality galvanisation.
Bottom section will be provided with plate welded to it for anchoring the mast to a
reinforced concrete foundation block. To increase the strength, gussets will be provided.
The bottom section will be accommodate winch, electric drive etc. and for the safety of the
same a vandal resistant and weather proof door will be provided with locking arrangement.
The fabricated and welded mast sections as detailed above will be hot dip galvanised with
a minimum thickness of coating 90 microns conforming to IS 4759-1996, IS: 2629-1990 &
IS: 2633-1992, both internally and externally.
After the delivery of the mast at site, these will be jointed by slip stressed fit method with
necessary stressing equipment. No site welding or bolted joints will be accepted. Earthing
terminal will be provided on the mast base and feeder pillar-box as per relevant ISS.
The mast will be provided with suitable aviation obstruction lamp.
4.03 Head Frame
The head frame designed to be a capping unit of the mast will be of welded steel
construction, galvanized internally and externally after assembly.
The head frame assembly will accommodate specially designed LM 6 die-cast pulleys to
accommodate the wire ropes and cable. Pulley construction will ensure that wire rope does
not jump out of the grooves.
The suspension arrangement for lantern carriage will be with three ropes of stainless steel
running on three on three pulleys for superior stability. There will be a separate pulley for
running the electric supply cable.
The pulleys will run on stainless steel shaft/spindles and will be self lubricating type.
The whole head frame assembly will be covered and protected by steel canopy, hot dip
galvanized internally and externally and secured to frame by stainless steel hardware.
4.04 Lantern Carriage
It will be of mild steel construction and hot dip galvanized internally and externally. The
lantern carriage will be so designed and fabricated to hold designed number of flood light
fittings and their control gearboxes, radically symmetrical. All junction boxes, Controlgear,
fittings etc. mounted on the lantern carriage will be on non-corrodable material with class of
protection IP 55.

BHILAI STEEL PLANT


At the top docking position, combined guides and stops will ensure concentricity between
the lantern carriage and the masthead. The stops will also help to ensure proper levelling
and positioning of the lantern carriage at its top position. All the lower docking position, the
lantern carriage will rest firmly at a maintainable height from the ground level with the help
of stoppers for ease of maintenance.
During lowering/raising operation the design will ensure that there is no damage caused to
the mast surface and any other parts installed.
4.05 Winch Assembly
The winch will be self sustaining and self lubricating type specially designed without the
need of breaks, springs or clutches, and will consist of two drums fabricated from steel with
machined grooves and mounted inside the mast at a convenient height from the base.
The wire rope will be wound on the drum with one end attached to the lantern carriage
while the other end is clamped to the winch drum. The design will ensure no inter winding
of the fitting ropes.
At least four turns of rope will remain on the drums when the lantern carriage is fully
lowered.
4.06 Support Ropes
The support ropes will be of stainless steel and will be capable of safely handling the
lantern carriage load.
4.07 Supply cables.
Power supply cables will be class B insulated with required number of cores provided with
multi-pin heavy duty locking type male/female connectors at the end. Pulley assembly will
accommodate extra cable for emergency supply.
Test load will be of 5-meter length 5-core 2.5-mm2 copper conductor cable with multi-pin
heavy duty locking type male/female connectors at the ends. Under no circumstances the
test lead will travel through the mast.
4.08 Foundation
The design and construction of foundation for high mast lighting tower will be included in
the scope of the contractor. The contactor will consider the following indicative data as
design parameter for high mast. However the actual data will be indicated during tender
scrutiny.
a) Soil bearing capacity at 1-Metre depth :- As per data supplied by Purchaser (BSP)
b) Wind speed :- As per data supplied by Purchaser (BSP)
c) The Contractor will submit the design drawings for approval of MECON for high mast
based on soil bearing capacity and wind speed. The Contractor will be responsible for
safe & efficient erection of the mast.
4.09 Electric Drive & Fittings
The drive will be 3 phase, 415 volt, 50 Hz, class B insulated, flameproof type induction
motor/geared motor with suitable torque limiter.
The motor will be mounted on MS hot dip galvanised plate inside the mast with a possibility
of adjusting its position. The drive will be capable of taking the load of whole lantern
carriage with luminaries, control gearboxes, aviation obstruction light mounted on it.
Manual handle will be supplied along with power tool for operating the winch manually in
case of power failure. Reversible type starters for motor, contactors for lighting circuit, MCB
isolator switch etc. will be provided in a flame proof & weatherproof enclosure.

BHILAI STEEL PLANT


4.10 Light Fittings
The light fittings will be of flood light type with twin 400-watt HPSV lamps. The quantity,
mounting position/angle and optical characteristics will be decided on the basis of the
following illumination requirement.
Minimum 30 lux illumination will be achieved at a horizontal distance of 30 meters from the
bottom of the mast all around. Illumination level of 10 lux will be sufficient at plant boundary
wall , parking area, Administrative Building, etc. Minimum of 3-5 lux is required to be
achieved at a horizontal distance of 125 Metre from the bottom of the mast towards all
area. Minimum 20 lux will be achieved in the areas adjoining at the perimeter of 40 meter
(approx.) radius considering the mast base at the centre.
All lighting performances will be checked holding the lux meter in horizontal plane at ground
level.

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STEEL AUTHORITY OF INDIA LIMITED

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